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2004 GMC Envoy Xuv

Owner reports · Recalls · Investigations

Limited comparison data

There is not enough comparable history to draw a useful model-year comparison.

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When problems were reported

Mileage at the reported incident

132 reports with mileage · 18 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 79 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 18 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Visibility. Review the 13 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

4 crash reports1 fire reports5 injury reports

Fuel/propulsion System complaints

8 reports
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159,000 miles · Feb 11, 2017
Fuel/propulsion System

I WAS DOING A REAR BRAKE JOB AND SMELLED GASOLINE, SO I WENT UNDER THE VEHICLE AND OBSERVED THERE WAS A WET SPOT ON THE REAR OF THE FUEL TANK. UPON CLOSER EXAMINATION I FOUND THE INLET PART OF THE FUEL TANK WAS BROKEN AND ALLOWING FUEL TO EXIT THE TANK, CAN WE SAY FIRE RISK, SO I WENT ONLINE TO TRY TO PURCHASE A REPLACEMENT TANK…

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I WAS DOING A REAR BRAKE JOB AND SMELLED GASOLINE, SO I WENT UNDER THE VEHICLE AND OBSERVED THERE WAS A WET SPOT ON THE REAR OF THE FUEL TANK. UPON CLOSER EXAMINATION I FOUND THE INLET PART OF THE FUEL TANK WAS BROKEN AND ALLOWING FUEL TO EXIT THE TANK, CAN WE SAY FIRE RISK, SO I WENT ONLINE TO TRY TO PURCHASE A REPLACEMENT TANK AND I FOUND WHERE SEVERAL PEOPLE HAD HAD THIS SAMEPROBLEM, BUT NO RECALL IS IN PLACE ?????

NHTSA ODI #10953971

67,245 miles · Jul 13, 2015
Fuel/propulsion System

STARTED SMELLING GAS, STARTED DRIPPING FUEL. AFTER INVESTIGATING THE FUEL LINES COMING OUT OF THE FUEL PUMP WERE SEVERELY CORRODED AT THE TOP OF THE GAS TANK. DRIPPING GAS COULD HAVE CAUGHT FIRE. LEARNED THERE WAS A TSB ON THIS AND EXTENDED WARRENTY DUE TO CORROSION OF FUEL LINES. THE WARRENTY WAS FOR 10 YEARS OR 150K. TH…

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STARTED SMELLING GAS, STARTED DRIPPING FUEL. AFTER INVESTIGATING THE FUEL LINES COMING OUT OF THE FUEL PUMP WERE SEVERELY CORRODED AT THE TOP OF THE GAS TANK. DRIPPING GAS COULD HAVE CAUGHT FIRE. LEARNED THERE WAS A TSB ON THIS AND EXTENDED WARRENTY DUE TO CORROSION OF FUEL LINES. THE WARRENTY WAS FOR 10 YEARS OR 150K. THE VEHICLE IS NOW 11 YEARS OLD. I HAVE LIVED IN THE SAME HOUSE FOR EIGHT YEARS AND NEVER RECEIVED A RECALL OR TSB NOTICE FROM GMC. OVER 800$ FOR A NEW FUEL PUMP AND TO DROP GAS TANK FOR REPAIRS. WHILE THE VEHICLE IS A 2004 IT ONLY HAS 67K ON IT.

NHTSA ODI #10733695

90,000 miles · Jun 15, 2015
Fuel/propulsion System

ABOUT 9-10 MONTHS AGO STARTED NOTICING A FUEL SMELL AROUND BACK OF TRUCK. REPLACED GAS CAP, BUT THE ODOR CONTINUED. INQUIRED AT LOCAL DEALER, BUT WAS TOLD THEY COULD NOT DETERMINE THE CAUSE. TRIED A LOCAL MECHANIC THAT I HAD USED BEFORE, BUT AT THAT TIME, THEY CLAIMED THEY FOUND NO CAUSE EITHER. ON MY THIRD TRIP TO LOCAL MECHANI…

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ABOUT 9-10 MONTHS AGO STARTED NOTICING A FUEL SMELL AROUND BACK OF TRUCK. REPLACED GAS CAP, BUT THE ODOR CONTINUED. INQUIRED AT LOCAL DEALER, BUT WAS TOLD THEY COULD NOT DETERMINE THE CAUSE. TRIED A LOCAL MECHANIC THAT I HAD USED BEFORE, BUT AT THAT TIME, THEY CLAIMED THEY FOUND NO CAUSE EITHER. ON MY THIRD TRIP TO LOCAL MECHANIC, WAS INFORMED THAT THERE IS A CRACK IN MY FILLER/GAS TANK CAUSING THE SMELL. FINALLY THEY FOUND THE CAUSE ONLY TO INFORM ME THAT NOW MY TRUCK IS BEYOND THE MILEAGE AND/OR DATE OF THE 'RECALL' THAT I WAS NEVER INFORMED ABOUT BY GMC ABOUT MY GAS TANK, AND IT WILL ONLY COST "ABOUT" $1200 TO REPLACE MY GAS TANK. I'VE RESIDED IN THE SAME HOME WELL LONGER THAN I'VE OWNED MY TRUCK, SO MY HOME ADDRESS, PHONE NUMBER AND EMAIL ARE ALL STILL THE SAME AS THEY WERE THEN, AND HAD NO NOTIFICATION THAT THEIR WAS ANY TYPE OF RECALL ON MY TRUCK. HAVE TRIED EMAILING AND SNAIL MAILING GMC ON MANY NUMEROUS OCCASIONS TO SEE IF I COULD GET ANY HELP WITH THE UNKNOWN OF RECALL, BUT HAVE YET TO RECEIVE ANY ANSWER WHAT'S SO EVER FROM THEM AT ALL. OBVIOUSLY, IF I HAD THE DISPOSABLE INCOME, I WOULD NOT BE PURSUING ANOTHER SOLUTION, BUT LIKE MANY, I CONTINUE TO LIVE PAYCHECK TO PAYCHECK AND MY TRUCK IS THE MAIN LIFELINE TO MAINTAIN WHAT LITTLE I CAN PROVIDE. IF YOU COULD PASS ALONG ANY INFORMATION ABOUT POSSIBLE RECALL ASSISTANCE I CAN RECEIVE, IT WOULD BE GREATLY APPRECIATED. THANK YOU *TR

NHTSA ODI #10725198

116,000 miles · Jun 11, 2015
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 GMC ENVOY XUV. WHILE DRIVING, THE CONTACT SMELLED FUEL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE FUEL PUMP WAS CORRODED AND THE ODOR WAS A RESULT OF A FUEL LEAK. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS …

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TL* THE CONTACT OWNS A 2004 GMC ENVOY XUV. WHILE DRIVING, THE CONTACT SMELLED FUEL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE FUEL PUMP WAS CORRODED AND THE ODOR WAS A RESULT OF A FUEL LEAK. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 116,000.

NHTSA ODI #10724742

128,452 miles · May 21, 2015
Fuel/propulsion System

AFTER REFUELING THE VEHICLE, A STRONG ODOR OF GASOLINE WAS PRESENT AND THE "SERVICE VEHICLE SOON" LIGHT WAS LIT. USING THE ON-STAR VEHICLE DIAGNOSTIC SERVICE, THE DIAGNOSTIC CODE INDICATED A FUEL SYSTEM LEAK OR LOOSE GAS CAP. HOWEVER, UPON INSPECTING THE VEHICLE IT WAS FOUND THAT THE FUEL TANK INLET CHECK VALVE, WHICH IS PART O…

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AFTER REFUELING THE VEHICLE, A STRONG ODOR OF GASOLINE WAS PRESENT AND THE "SERVICE VEHICLE SOON" LIGHT WAS LIT. USING THE ON-STAR VEHICLE DIAGNOSTIC SERVICE, THE DIAGNOSTIC CODE INDICATED A FUEL SYSTEM LEAK OR LOOSE GAS CAP. HOWEVER, UPON INSPECTING THE VEHICLE IT WAS FOUND THAT THE FUEL TANK INLET CHECK VALVE, WHICH IS PART OF THE FUEL TANK, WAS FRACTURED AND LEAKING FUEL. IN CHECKING WITH GMC, THERE WAS AN EXISTING NHTSA ACTION NUMBER: PE07014 CONCERNING THIS DEFECT FOR MY MAKE/MODEL/YEAR VEHICLE. A GMC SPECIAL COVERAGE POLICY EXTENSION (07099A) WAS ALSO IN EFFECT SINCE 2007 FOR 10 YEARS OR 150,000 MILES TO EFFECTIVELY REPAIR THIS KNOWN FUEL TANK DEFECT. THIS REPAIR INVOLVES A COMPLETE REPLACEMENT OF THE FUEL TANK. HOWEVER, GMC REFUSED TO REPLACE THE FUEL TANK AND COVER THE COST OF REPAIR BECAUSE MY VIN NUMBER WAS NOT IN THE LISTED RANGE. IN TRYING TO REPAIR THE VEHICLE IT WAS FOUND THAT THESE FUEL TANKS ARE ON BACKORDER FROM GM AS I SUSPECT MANY GMC ENVOY OWNERS ARE NOW BECOMING AWARE OF THIS SERIOUS DEFECT AND WERE NOT INFORMED AT THE INITIAL RECALL BECAUSE LIKE MY VEHICLE, THEY WERE NOT ON THE VIN NUMBER COVERAGE LIST. OBVIOUSLY THE GM VIN NUMBER RANGE FOR THIS DEFECT IS INCORRECT AND SHOULD BE EXPANDED TO COVER ALL KNOWN 2002-2004 ENVOY, ENVOY XL AND ENVOY XUV MODEL VEHICLES. THE COST OF REPAIR WAS OVER $1400. GMC IS THE ONLY SOURCE FOR THIS FUEL TANK AS THERE ARE NO OTHER OEM VENDORS. THIS IS A DANGEROUS DEFECT OF WHICH I BELIEVE MANY GMC ENVOY OWNERS ARE NOT AWARE OF AND CAN LEAD TO EXPLOSION AND SERIOUS INJURY IF LEFT UNDETECTED. GMC NEEDS TO RE-EVALUATE THE VIN NUMBER RANGES AND NOTIFY ALL MAKE/MODEL/YEAR OWNERS IMMEDIATELY TO CHECK FOR FUEL TANK LEAKAGE AND IF NECESSARY, COVER THE COST OF REPLACEMENT AND REPAIR. I HAVE SAVED THE FUEL TANK AND REPAIR RECEIPTS AND CAN SUPPLY PICTURES OF THE DEFECT IF REQUIRED/REQUESTED.

NHTSA ODI #10717576

123,000 miles · Sep 17, 2014
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 GMC ENVOY XUV. THE CONTACT STATED THAT THE FUEL WAS LEAKING UNDERNEATH THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE TECHNICIAN DIAGNOSED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXI…

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TL* THE CONTACT OWNS A 2004 GMC ENVOY XUV. THE CONTACT STATED THAT THE FUEL WAS LEAKING UNDERNEATH THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE TECHNICIAN DIAGNOSED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 123,000.

NHTSA ODI #10636939

129,824 miles · Mar 20, 2014
Exterior LightingFuel/propulsion System

WENT TO REPLACE HEAD LIGHT BULB TO FIND OUT THAT I HAD TO REPLACE THE WIRING DO TO IT WAS MELTED. THE FILLER NECK ON THE FUEL TANK IS CRACKED, CAUSING AN EVAP LEAK IN WITCH I FOUND OUT THROUGH A GARAGE AND 5 DIFF. SALVAGE YARDS. AND LAST, 6 DIFF. TIMES WILL DRIVING I LOST POWER WILL DRIVING. I HAD TO TURN THE IGNITION OFF, WAIT…

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WENT TO REPLACE HEAD LIGHT BULB TO FIND OUT THAT I HAD TO REPLACE THE WIRING DO TO IT WAS MELTED. THE FILLER NECK ON THE FUEL TANK IS CRACKED, CAUSING AN EVAP LEAK IN WITCH I FOUND OUT THROUGH A GARAGE AND 5 DIFF. SALVAGE YARDS. AND LAST, 6 DIFF. TIMES WILL DRIVING I LOST POWER WILL DRIVING. I HAD TO TURN THE IGNITION OFF, WAIT ABOUT 3 SEC. BEFORE IT WOULD START AND GO. THE FIRST TIME WAS IN THE MIDDLE OF AN INTERSECTION AND THE REST HAPPENED WHILE ON A REGULAR ROAD. I EXPLAINED TO MY WIFE WHAT TO DO IF THIS HAPPENS TO HER AND IT DID ONCE, THE OTHERS WHILE I WAS DRIVING. *TR

NHTSA ODI #10573870

84,925 miles · Jul 19, 2012
Electrical SystemFuel/propulsion System

WHEN IN TRAFFIC TRAVELING ACROSS STATES ON HIGHWAY AT 55-65 MPH LEFT LANE(SCARY) I RAN OUT OF GAS WHEN THE GAUGE SHOWED 1/4 OF A TANK NOW WHEN TANK IS FULL IT READ 1/2 AND AT TIMES THE GAUGE FLOATS AROUND FULL TO EMPTY WHEN DRIVING SOME TIME IT READS EMPTY WHEN I PUT 10 GALLONS IN WAS TOLD A BAD FUEL SENDER IN TANK I READ OTHER …

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WHEN IN TRAFFIC TRAVELING ACROSS STATES ON HIGHWAY AT 55-65 MPH LEFT LANE(SCARY) I RAN OUT OF GAS WHEN THE GAUGE SHOWED 1/4 OF A TANK NOW WHEN TANK IS FULL IT READ 1/2 AND AT TIMES THE GAUGE FLOATS AROUND FULL TO EMPTY WHEN DRIVING SOME TIME IT READS EMPTY WHEN I PUT 10 GALLONS IN WAS TOLD A BAD FUEL SENDER IN TANK I READ OTHER REPORTS THAT G M RECALL WILL ONLY PAY HALF THE COST TO REPAIR?? *TR

NHTSA ODI #10466613

Official recalls

0

No recalls in this snapshot.

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

2

RQ17002 · 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.

PE05006 · Turn Signal Failures

Opened Feb 4, 2005 · Closed May 6, 2005

Status: closed (inferred from source dates) · Exterior Lighting:turn Signal; Exterior Lighting:turn Signal:flasher Unit; Exterior Lighting:turn Signal:switch

BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.

Additional source detail variants (3)

Exterior Lighting:turn Signal:flasher Unit

BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.

Exterior Lighting:turn Signal

BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.

Exterior Lighting:turn Signal:switch

BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.