IllustrationEXHAUST MANIFOLD FAILURE. MECHANIC SAYS IN 25 YEARS HE HAS NEVER SEEN AS MANY FAILURES AS IN THESE MODELS,AS IT IS USUALLY VERY RARE FOR THEM TO FAIL. IN RESEARCHING ON LINE I HAVE FOUND IT IS A COMMON PROBLEM IN '03 THROUGH '08 MODEL GMC ENVOYS AND CHEVY TRAILBLAZERS. *TR
2005 GMC Envoy
Owner reports · Recalls · Investigations
More warning signs than most Envoy years
Owner complaints for the 2005 GMC Envoy are substantially higher than the model-year median of 22.
About this comparison →How this year compares
Owner complaints by model year
Compare all Envoy years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
280–25K
5925–50K
8750–75K
10775–100K
88100–150K
16150K+
385 reports with mileage · 103 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Electrical System. Review the 183 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel System, Gasoline. Review the 164 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Exterior Lighting. Review the 45 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
27 crash reports14 fire reports22 injury reports
What owners actually said
488 reportsTHE FUEL SENSING SYSTEM HAS FAILED. THE FIRST SYMPTOM WAS A FUEL GAUGE REGISTERING 0 AND A CHECK FUEL LEVEL MESSAGE AFTER I HAD JUST FILLED THE TANK. FOR A PERIOD OF TIME, THE GAUGE WOULD SLOWLY CLIMB TO SLIGHTLY ABOVE HALF FULL, BUT OFTEN RETURN TO 0 WITH THE MESSAGE OCCURRING WHENEVER STOPPING THE CAR OR ON ENGINE STARTUP. NOW…
Read full complaint
THE FUEL SENSING SYSTEM HAS FAILED. THE FIRST SYMPTOM WAS A FUEL GAUGE REGISTERING 0 AND A CHECK FUEL LEVEL MESSAGE AFTER I HAD JUST FILLED THE TANK. FOR A PERIOD OF TIME, THE GAUGE WOULD SLOWLY CLIMB TO SLIGHTLY ABOVE HALF FULL, BUT OFTEN RETURN TO 0 WITH THE MESSAGE OCCURRING WHENEVER STOPPING THE CAR OR ON ENGINE STARTUP. NOW THE GAUGE SELDOM GOES ABOVE A QUARTER FULL, EVEN THOUGH I TYPICALLY KEEP THE TANK MORE THAN HALF FULL. I AM ABLE TO ESTIMATE FUEL CONSUMED USING THE TRIP ODOMETER, BUT THIS IS NOT SATISFACTORY. THIS HAS BEEN GOING ON FOR A YEAR AND THE DEALER IS UNWILLING TO ACCEPT RESPONSIBILITY FOR FIXING IT. *TR
FUEL LEVEL SENSOR READS FULL AND GOES TO EMPTY BACK AND FORTH AND TURNS ON CHECK ENGINE LIGHT . THIS OCCURES WITH ANY AMOUNT OF FUEL IN TANK FULL TO EMPTY. HAS NOT BEEN REPAIRED AS GM WILL NOT STAND BEHIND PARTS . MY CONCERNE IS WITH CHECK ENGINE LIGHT ON HOW WILL I KNOW IF SOMETHING ELSE IS TO FAIL , SUCH AS BRAKES EXT. TALKED…
Read full complaint
FUEL LEVEL SENSOR READS FULL AND GOES TO EMPTY BACK AND FORTH AND TURNS ON CHECK ENGINE LIGHT . THIS OCCURES WITH ANY AMOUNT OF FUEL IN TANK FULL TO EMPTY. HAS NOT BEEN REPAIRED AS GM WILL NOT STAND BEHIND PARTS . MY CONCERNE IS WITH CHECK ENGINE LIGHT ON HOW WILL I KNOW IF SOMETHING ELSE IS TO FAIL , SUCH AS BRAKES EXT. TALKED TO GM COMPLAINT DEPT. AND WAS TOLD THEY HAD NO KNOWLEDGE . YEA RIGHT. SEEMS MOST GM SUV'S ARE HAVING THE SAME PROBLEM . *TT
OUR 2005 GMC ENVOY HAS ALWAYS HAD A FAULTY FUEL GAUGE AND HAS CAUSED OUR FAMILY TO BE STRANDED A FEW TIMES WITHOUT GAS WHILE TRAVELING FAR FROM HOME. WE TOOK IT INTO A GMC DEALER WHO WANTED $ 950 FOR PARTS AND REPAIRS. WE JUST DON'T HAVE THAT KIND OF MONEY. GMC HAS ALWAYS BEEN AWARE OF THIS PROBLEM AND HAS NOT OFFERED TO FIX…
Read full complaint
OUR 2005 GMC ENVOY HAS ALWAYS HAD A FAULTY FUEL GAUGE AND HAS CAUSED OUR FAMILY TO BE STRANDED A FEW TIMES WITHOUT GAS WHILE TRAVELING FAR FROM HOME. WE TOOK IT INTO A GMC DEALER WHO WANTED $ 950 FOR PARTS AND REPAIRS. WE JUST DON'T HAVE THAT KIND OF MONEY. GMC HAS ALWAYS BEEN AWARE OF THIS PROBLEM AND HAS NOT OFFERED TO FIX IT NOR HAVE A RECALL ON THIS FAULTY GAS GAUGE. 856,000 GM SUVS UNDER INVESTIGATION FOR FAULTY FUEL GAUGES FEDERAL REGULATORS ARE INVESTIGATING 865,000 GENERAL MOTORS SUVS, INCLUDING THE 2005- ?07 CHEVROLET TRAILBLAZER AND BUICK RAINIER,FOR FAULTY FUEL GAUGES THAT ARE INACCURATE. THE 2005-?06 CHEVROLET TRAILBLAZER EXT, THE 2005-?07 GMC ENVOY, THE 2005-?06 GMC ENVOY AND THE 2005-?07 SAAB 9-7X ARE ALSO AFFECTED VEHICLES BEING INVESTIGATED.
I PURCHASED THIS CAR USED WITH APPROXIMATELY 24,000 MILES IN 2006. WITHIN A YEAR OF PURCHASING THE CAR THE CLUSTER PANEL (GAUGES) STOPPED WORKING. I TOOK THE CAR IN TO HAVE IT CHECKED AND WAS TOLD THAT THERE WAS NO RECALL AND THAT IT WOULD COST APPROXIMATELY $700 TO REPAIR AS THE ENTIRE CLUSTER PANEL WOULD HAVE TO BE REMOVE AND …
Read full complaint
I PURCHASED THIS CAR USED WITH APPROXIMATELY 24,000 MILES IN 2006. WITHIN A YEAR OF PURCHASING THE CAR THE CLUSTER PANEL (GAUGES) STOPPED WORKING. I TOOK THE CAR IN TO HAVE IT CHECKED AND WAS TOLD THAT THERE WAS NO RECALL AND THAT IT WOULD COST APPROXIMATELY $700 TO REPAIR AS THE ENTIRE CLUSTER PANEL WOULD HAVE TO BE REMOVE AND REPLACED. AFTER TALKING WITH CO-WORKERS WITH THE SAME VEHICLE EXPERIENCING THE SAME PROBLEM; I LATER DISCOVERED THAT THERE HAD BEEN A RECALL ON THIS ISSUE BUT YOU HAD TO BE THE FIRST OWNER OF THE VEHICLE. AFTER HAVING THE CLUSTER PANEL REPAIRED, MY GAS GAUGE HAS STOPPED WORKING AND I AM TOLD THAT THE ENTIRE TANK HAS TO BE REMOVED FOR REPAIR AND THAT THERE HAS NOT BEEN A RECALL ON THIS ISSUE EITHER. THE WINDOW AND DOOR LOCK SYSTEM ON THE FRONT PASSENGER DOOR ALSO IS NON-OPERATIONAL. THIS VEHICLE SEEMS TO HAVE SEVERAL MINOR ELECTRICAL ISSUES BUT I AM MOST DISTURBED BY THE FACT THAT AFTER SPENDING THE MONEY TO HAVE THE CLUSTER PANEL FIXED MY GAS GAUGE IS STILL NOT WORKING PROPERLY.
GAS GAUGE AND SPEEDOMETER NO LONGER WORK. NEVER KNOW HOW MUCH GAS IS IN THE CAR. *KB
WHEN I FILL THE GAS TANK, THE GAUGE GOES TO EMPTY AND STAYS THERE FOR A WHILE UNTIL IT FINALLY SEEMS TO CORRECT ITSELF BUT I AM UNSURE IF IT IS CORRECT AT ALL TIMES AND AFRAID IT WILL SHOW THERE IS GAS AND RUN OUT. I HAVE SEEN WHERE SEVERAL OF ENVOY OWNERS ARE HAVING THE SAME ISSUE. I FEEL GM SHOULD MAKE CORRECT THESE SENSORS.
IN 2008 THE GAS GAUGE TO MY 2005 GMC ENVOY STOPPED WORKING. I WOULD FILL UP THE TANK AND THE READER WOULD NOT MOVE AT ALL. IT ALWAYS SHOWED EMPTY. I TOOK IT TO A MECHANIC AND THEY TOLD ME IT WOULD COST $900 TO FIX. I RAN OUT OF GAS SEVERAL TIMES ON THE FREEWAY AND STREETS. THIS IS VERY DANGEROUS. ARE THESE NO RECALLS FOR TH…
Read full complaint
IN 2008 THE GAS GAUGE TO MY 2005 GMC ENVOY STOPPED WORKING. I WOULD FILL UP THE TANK AND THE READER WOULD NOT MOVE AT ALL. IT ALWAYS SHOWED EMPTY. I TOOK IT TO A MECHANIC AND THEY TOLD ME IT WOULD COST $900 TO FIX. I RAN OUT OF GAS SEVERAL TIMES ON THE FREEWAY AND STREETS. THIS IS VERY DANGEROUS. ARE THESE NO RECALLS FOR THIS ISSUE? SEEMS LIKE ALOT OF OTHER OWNERS ARE HAVING THE SAME ISSUE. *TR
FUEL GAUGE STARTED GOING FROM FULL TO EMPTY (AFTER FILLING), AND NOW IT PRETTY MUCH IS IN THE EMPTY POSITION EVEN WITH THE TANK FULL. VEHICLE HAS 79K MILES. LOW FUEL WARNING LAMP AND SOUND ARE ENGAGED. *TR
TL* THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT STATED THAT THE FUEL GAUGE DISPLAYED ERRATIC READINGS. WHEN THE FUEL TANK WAS EMPTY, THE FUEL GAUGE WOULD INDICATE THAT FUEL WAS PRESENT IN THE TANK. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO STATED THAT THEY WOULD HAVE TO REPLACE THE FUEL SENSOR. THERE WERE NO RECALLS …
Read full complaint
TL* THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT STATED THAT THE FUEL GAUGE DISPLAYED ERRATIC READINGS. WHEN THE FUEL TANK WAS EMPTY, THE FUEL GAUGE WOULD INDICATE THAT FUEL WAS PRESENT IN THE TANK. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO STATED THAT THEY WOULD HAVE TO REPLACE THE FUEL SENSOR. THERE WERE NO RECALLS OR WARRANTIES ADDRESSING THIS FAILURE. THE MANUFACTURER WAS NOT NOTIFIED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 70,000. THE VIN WAS UNKNOWN.
Official recalls
206V417000 · Air Bags:frontal
Oct 31, 2006
CERTAIN VEHICLES ORIGINALLY BUILT WITH CLOTH SEATS THAT WERE EQUIPPED WITH AN AUTOMATIC AIR BAG PASSENGER SENSING SYSTEM AND LATER REUPHOLSTERED WITH AFTERMARKET LEATHER SEAT COVER KITS ARE INVOLVED. TESTING HAS INDICATED THAT THE AFTERMARKET LEATHER SEAT COVERS CAN CAUSE THE PASSENGER SENSING SYSTEM TO MALFUNCTION.
Consequence & remedy
Consequence: IF THE PASSENGER SENSING SYSTEM MALFUNCTIONS, THE FRONT AIR BAG ON THE PASSENGER SIDE MAY BE DISABLED WHEN IT SHOULD BE ENABLED, OR ENABLED WHEN IT SHOULD BE DISABLED. IN EITHER CASE, IN THE EVENT OF A CRASH THAT REQUIRES AIR BAG DEPLOYMENT, A FRONT PASSENGER'S LEVEL OF INJURY MAY BE INCREASED.
Remedy: BECAUSE A REPLACEMENT LEATHER SEAT COVER THAT IS COMPATIBLE WITH THE PASSENGER SENSING SYSTEM IS NOT AVAILABLE, GENERAL MOTORS (GM) WILL REPURCHASE THESE VEHICLES IN ACCORDANCE WITH THE TERMS STATED IN GM'S LETTER TO OWNERS. THE RECALL BEGAN ON NOVEMBER 6, 2006. OWNERS SHOULD CONTACT GM AT 1-877-477-1022 TO BEGIN THE PROCESS OF REPURCHASING THEIR VEHICLE.
05V035000 · Visibility:windshield
Feb 3, 2005
CERTAIN SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 212, 'WINDSHIELD MOUNTING.' THE WINDSHIELD URETHANE BEAD MAY NOT HAVE ADHERED TO THE BODY IN CERTAIN AREAS DURING THE CURE PROCESS.
Consequence & remedy
Consequence: IF A CRASH OCCURS, THE WINDSHIELD MAY NOT BE RETAINED, INCREASING THE RISK OF INJURY TO A VEHICLE OCCUPANT.
Remedy: DEALERS WILL REPLACE THE WINDSHIELD FREE OF CHARGE. THE RECALL BEGAN ON MARCH 10, 2005. OWNERS MAY CONTACT BUICK AT 1-866-608-8080, CHEVROLET AT 1-800-630-2438, OR GMC AT 1-866-996-9463.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
2RQ17002 · Loss Of Headlights
Opened Apr 24, 2017 · Closed Mar 29, 2021
Status: closed (inferred from source dates) · Exterior Lighting:headlights
The subject vehicles are model year (MY) 2002-2009 Chevrolet Trailblazer, GMC Envoy, 2004-2007 Buick Rainier, 2003-2008 Isuzu Ascender, 2005-2009 Saab 9-7X, 2002-2004 Oldsmobile Bravada, 2003-2006 Chevrolet SSR, 2005-2009 Buick Lacrosse, and 2006-2008 Pontiac Grand Prix. This scope includes the Trailblazer/Envoy variants: 2002-2006 Envoy XL/Trailblazer EXT and 2004-2005 Envoy XUV. The original scope of this investigation was expanded to include all vehicles equipped with the subject Headlight Driver Module (HDM). The focus of the investigation was to determine whether actions performed by General Motors adequately addressed any unreasonable risk to motor vehicle safety in the subject vehicles concerning the headlights and the HDM that controls them.Under normal electrical load and environmental conditions, the HDM can overheat inside the Underhood Electrical Center (UEC). This can cause the module to fail and result in a simultaneous loss of both low beam headlights and both daytime running lights (DRLs), often with no warning or prior detectability to the driver. This failure can be intermittent or permanent. No other exterior lights are affected. High beams, turn signals, brake lights, and reverse lights are still operational.General Motors addressed this issue with 2 recalls (14V755 & 15V519) and a special coverage program (N172091910). In view of the recalls and special coverage program implemented by GM and the vehicle high beams continuing to operate, ODI has tentatively concluded that the actions taken by GM mitigate any unreasonable risk to safety posed by HDM failure in the subject vehicles.Accordingly, the investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take additional action if warranted by new circumstances.The ODI reports cited above are available for review online at NHTSA.gov under the identification numbers in the attached document.
DP10001 · Fuel Level Gauge System Failure
Opened Jan 7, 2010 · Closed May 23, 2011
Status: closed (inferred from source dates) · Fuel System, Other; Fuel System, Other:storage:fuel Gauge System
The Office of Defects Investigation has received 668 complaints alleging inaccurate fuel gauge reading while driving in model year 2005-07 Chevrolet Trailblazer, GMC Envoy, Buick Rainier, and Saab 9-7x vehicles.Of the 668 complaints, 58 incidents were alleged to result in a vehicle stall.Of the 58 stalling incidents, 43 complaints reported stalling because the fuel level reading indicated more fuel availability than what is actually in the fuel tank. One complaint alleged a vehicle crash after the vehicle stalled while exiting the interstate, became disabled, and was struck from behind.Summarily, the complaints show an apparent increasing trend, with most complaints received within the past year.A Preliminary Evaluation has been opened to assess the scope, frequency and potential safety consequences associated with the alleged defect.
Additional source detail variants (2)
Fuel System, Other
The Office of Defects Investigation has received 668 complaints alleging inaccurate fuel gauge reading while driving in model year 2005-07 Chevrolet Trailblazer, GMC Envoy, Buick Rainier, and Saab 9-7x vehicles.Of the 668 complaints, 58 incidents were alleged to result in a vehicle stall.Of the 58 stalling incidents, 43 complaints reported stalling because the fuel level reading indicated more fuel availability than what is actually in the fuel tank. One complaint alleged a vehicle crash after the vehicle stalled while exiting the interstate, became disabled, and was struck from behind.Summarily, the complaints show an apparent increasing trend, with most complaints received within the past year.A Preliminary Evaluation has been opened to assess the scope, frequency and potential safety consequences associated with the alleged defect.
Fuel System, Other:storage:fuel Gauge System
The Office of Defects Investigation has received 668 complaints alleging inaccurate fuel gauge reading while driving in model year 2005-07 Chevrolet Trailblazer, GMC Envoy, Buick Rainier, and Saab 9-7x vehicles.Of the 668 complaints, 58 incidents were alleged to result in a vehicle stall.Of the 58 stalling incidents, 43 complaints reported stalling because the fuel level reading indicated more fuel availability than what is actually in the fuel tank. One complaint alleged a vehicle crash after the vehicle stalled while exiting the interstate, became disabled, and was struck from behind.Summarily, the complaints show an apparent increasing trend, with most complaints received within the past year.A Preliminary Evaluation has been opened to assess the scope, frequency and potential safety consequences associated with the alleged defect.