← New search

2004 GMC Envoy

Owner reports · Recalls · Investigations

More warning signs than most Envoy years

Owner complaints for the 2004 GMC Envoy are substantially higher than the model-year median of 22.

About this comparison →

When problems were reported

Mileage at the reported incident

288 reports with mileage · 79 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 164 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Exterior Lighting. Review the 39 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel/propulsion System. Review the 38 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

25 crash reports11 fire reports22 injury reports

What owners actually said

367 reports
150,000 miles · Dec 12, 2019
Electrical SystemSeatsUnknown Or OtherFire

FRONT PASSENGER SEAT CAUGHT ON FIRE FROM THE SEAT HEATER. THE VEHICLE PARKED AND TURNED OFF. IT WAS PARKED IN A HIGH SCHOOL PARKING LOT WHILE MY DAUGHTER WAS IN SCHOOL. WE CONTACTED GMC, BUT THEY SAID IT THERE WAS NOTHING THEY COULD DO. THERE WAS SOMETHING THAT WENT WRONG FOR IT TO JUST CATCH FIRE. CAN YOU HELP US IN ANYWAY AT A…

Read full complaint

FRONT PASSENGER SEAT CAUGHT ON FIRE FROM THE SEAT HEATER. THE VEHICLE PARKED AND TURNED OFF. IT WAS PARKED IN A HIGH SCHOOL PARKING LOT WHILE MY DAUGHTER WAS IN SCHOOL. WE CONTACTED GMC, BUT THEY SAID IT THERE WAS NOTHING THEY COULD DO. THERE WAS SOMETHING THAT WENT WRONG FOR IT TO JUST CATCH FIRE. CAN YOU HELP US IN ANYWAY AT ALL.

NHTSA ODI #11288638

130,000 miles · Dec 6, 2019
SeatsFire

BOTTOM DRIVER SIDE SEAT WARMER CAUGHT SEAT ON FIRE. MELTED A HOLE IN THE SEAT SURFACE, BLISTERED WIFE'S LEG. THIS HAPPENED DURING HER MORNING COMMUTE TO WORK ON CITY SURFACE STREETS

NHTSA ODI #11287526

100,000 miles · Nov 22, 2019
Wheels

SPARE TIRE RELEASE MECHANISM DYSFUNCTIONAL. I WAS UNABLE TO CHANGE TO CHANGE A FLAT WHILE ON THE SIDE OF A VERY BUSY HIGHWAY. HAD THE VEHICLE TOWED TO A AUTOMOTIVE TIRE AND REPAIR BUSINESS, AND THEY COULD NOT REMOVE THE SPARE EITHER. I SEARCHED ONLINE AND THERE ARE A NUMBER OF SIMILAR REPORTS/COMPLAINTS CONCERNING GMC TRUCKS …

Read full complaint

SPARE TIRE RELEASE MECHANISM DYSFUNCTIONAL. I WAS UNABLE TO CHANGE TO CHANGE A FLAT WHILE ON THE SIDE OF A VERY BUSY HIGHWAY. HAD THE VEHICLE TOWED TO A AUTOMOTIVE TIRE AND REPAIR BUSINESS, AND THEY COULD NOT REMOVE THE SPARE EITHER. I SEARCHED ONLINE AND THERE ARE A NUMBER OF SIMILAR REPORTS/COMPLAINTS CONCERNING GMC TRUCKS AND SUVS, AT LEAST 2002-2012 MODELS. MINE IS A 2004 ENVOY. E.G. HTTP://WWW.CARPROBLEMZOO.COM/GMC/ENVOY/SPARE-TIRE-PROBLEMS.PHP THIS DESIGN FAILURE COULD LEAD TO SIGNIFICANT INJURY OR ADVERSE HEALTH IMPACTS (EXPOSURE, HYPOTHERMIA, ETC.) ESPECIALLY TO ELDERLY OR INABILITY TO CHANGE A FLAT WHILE IN REMOTE TERRAIN, OR AREAS WITHOUT CELL PHONE SERVICE. THERE IS NO SAFETY RELEASE BACKUP THAT WOULD ALSO BYPASSING THE DEFECTIVE TIRE RELEASE MECHANISM.

NHTSA ODI #11281795

196,425 miles · Nov 21, 2019
Fuel/propulsion SystemPower TrainUnknown Or Other

THE TRANSMISSION STARTED TO SLIP, NOTICED IT STARTING TO HAVE ISSUES GETTING UP TO PROPER SPEED WITHOUT SLIPPING AND TRYING TO STALL, AND WAS TOLD BY PREVIOUS OWNER WHOM I'M PURCHASING IT FROM THAT THERE IS A POSSIBLE ISSUE WITH THE TRANSFER CASE AS WELL, AS IT ENGAGES IT'S 4 WHEEL DRIVE WITHOUT ME TOUCHING IT, TRIED TO SERVICE …

Read full complaint

THE TRANSMISSION STARTED TO SLIP, NOTICED IT STARTING TO HAVE ISSUES GETTING UP TO PROPER SPEED WITHOUT SLIPPING AND TRYING TO STALL, AND WAS TOLD BY PREVIOUS OWNER WHOM I'M PURCHASING IT FROM THAT THERE IS A POSSIBLE ISSUE WITH THE TRANSFER CASE AS WELL, AS IT ENGAGES IT'S 4 WHEEL DRIVE WITHOUT ME TOUCHING IT, TRIED TO SERVICE THE TRANSMISSION AND PUT FRESH FLUID AND A NEW FILTER IN TO SEE IF IT WOULD HELP AND NOW IT CAN ONLY GO AS FAST AS 40 TO 55 BEFORE IT STARTS TO SLIP PRETTY BAD. I HAVE A BABY ON THE WAY DUE IN THE NEXT COUPLE WEEKS AND WITH IT SLIPPING AND DROPPING SPEED IT CAN CAUSE ME TO END UP GETTING HIT AND I DON'T WANT TO PUT MINE, MY CHILD, OR ANY OF MY OTHER PASSENGERS IN DANGER.

NHTSA ODI #11281475

169,000 miles · Oct 6, 2019
Air Bags

WAS DRIVING DOWN THE ROAD AND THE REPAIR SAFETY AIR BAG LIGHT CAME ON AND IS STILL ON

NHTSA ODI #11266637

236,550 miles · Oct 3, 2019
Exterior LightingCrash

WHILE DRIVING AT NIGHT BOTH LOW BEAM HEADLIGHTS GO OUT COMPLETELY WITHOUT WARNING. VEHICLE TRAVELING AT HIGHWAY SPEED AND HAS HAPPENED WHILE DRIVING IN CITY AS WELL. HIGHBEAM HEADLIGHTS WORK WHEN SWITCHED ON AFTER LOW BEAM STOP WORKING. CANNOT LEAGALLY DRIVE WITH HIGHBEAMS ON ALWAYS. MY ENVOY IS IN EXCELLENT CONDITION AND IS…

Read full complaint

WHILE DRIVING AT NIGHT BOTH LOW BEAM HEADLIGHTS GO OUT COMPLETELY WITHOUT WARNING. VEHICLE TRAVELING AT HIGHWAY SPEED AND HAS HAPPENED WHILE DRIVING IN CITY AS WELL. HIGHBEAM HEADLIGHTS WORK WHEN SWITCHED ON AFTER LOW BEAM STOP WORKING. CANNOT LEAGALLY DRIVE WITH HIGHBEAMS ON ALWAYS. MY ENVOY IS IN EXCELLENT CONDITION AND IS DEALER SERVICED EVEN THOUGH IT HAS HIGH MILEAGE. THERE WAS A RECALL FOR 2006 AND UP FOR THIS TYPE ISSUE, WHY WAS THE 2004 MODEL YEAR NOT LOOKED AT? THERE ARE OTHERS THAT HAVE HAD THE SAME ISSUE WITH LOWBEAM HEADLIGHTS. FUSEBOX UNDERHOOD IS LABELED TO CONFUSE OWNER AND RELAYS NOT DESCRIBED WELL IN OWNERS MANUAL. THERE IS NO RELAY LISTED FOR LOW BEAM HEADLIGHTS. HEADLIGHT DRIVER MODULE IS A KNOW FAILURE COMPONENT. GM ALSO CHANGED ONSTAR TO DIGITAL SYSTEM LEAVING GM CARS LIKE MINE WITH ANALOG ONSTAR UNSERVICABLE AND REQUIRES EXPENSIVE UPGRADE. HEADLIGHTS GOING DARK WHILE DRIVING AT NIGHT IS A DANGER AND VEHICLE SHOULD BE REQUIRED TO FALL UNDER RECALL FOR 2006 MODELS AS WELL. SLIGHT ACCIDENT, RAN OFF ROAD INTO DITCH AND CAUSED LIGHT DAMAGE. VEHICLE WAS ABLE TO BE DRIVEN, BUT NEEDED SOME REPAIR.

NHTSA ODI #11265946

230,000 miles · Oct 1, 2019
Fuel/propulsion System

WHILE DRIVING ON THE STREET ON MY WAY HOME FROM WORK , I COULD SMELL GAS... GOT OUT AND SAW A VISIBLE LEAK COMING FROM THE GAS TANK.. I PROCEEDED TO LOOK THIS PROBLEM UP, AND FOUND OUT THIS IS A REOCCURRING PROBLEM WITH THIS VEHICLE .

NHTSA ODI #11265284

67,000 miles · Sep 26, 2019
Electrical SystemExterior LightingService Brakes

MY DASH PANEL GAUGES BEGAN FAILING ONE BY ONE. MY HEADLIGHTS WILL SOMETIMES NOT COME ON AFTER STARTING THE CAR WITH THE HEADLIGHT SWITCH ON AUTO. A FLICK OF THE HEADLIGHT SWITCH IN AND OFF, DOES NOT MAKE THE HEADLIGHTS COME ON. SOMETIMES THEY COME ON AFTER DRIVING AROUND, AND THEN WILL GO OFF WITHOUT TOUCHING THE SWITCH. NOW, M…

Read full complaint

MY DASH PANEL GAUGES BEGAN FAILING ONE BY ONE. MY HEADLIGHTS WILL SOMETIMES NOT COME ON AFTER STARTING THE CAR WITH THE HEADLIGHT SWITCH ON AUTO. A FLICK OF THE HEADLIGHT SWITCH IN AND OFF, DOES NOT MAKE THE HEADLIGHTS COME ON. SOMETIMES THEY COME ON AFTER DRIVING AROUND, AND THEN WILL GO OFF WITHOUT TOUCHING THE SWITCH. NOW, MY SIDE BRAKELIGHTS WILL NOT OPERATE CORRECTLY WHEN THE BRAKE PEDAL IS PRESSED. ONLY THE THIRD BRAKE LIGHT ILLUMINATES.

NHTSA ODI #11258245

Mileage unknown · Sep 16, 2019
Air Bags

THE SEAT BELT WAS ALWAYS ON SO I HAVE TO REPLACE THE BOTH IMPACTOR SENSOR.

NHTSA ODI #11255639

Mileage unknown · Aug 18, 2019
Visibility/wiper

BACK WINDOW SPONTANEOUSLY BUST. 2 TIMES IT AS HAPPEN LESS THEN 1YEAR APART ON MY THIRD WINDOW IT BLEW UP IN MY WIFE'S FACE THE SECOND TIME

NHTSA ODI #11244822

Official recalls

1

05V198000 · Exterior Lighting:turn Signal

May 5, 2005

ON CERTAIN TRUCKS AND SPORT UTILITY VEHICLES, THE DRIVER WISHING TO SIGNAL A TURN BY MOVING THE DIRECTIONAL SIGNAL LEVER, (UP OR DOWN) MAY CAUSE THE FRONT MARKER/TURN LIGHTS AND REAR TURN LIGHTS TO FLASH IN A MANNER SIMILAR TO HAZARD WARNING, RATHER THAN FLASHING ON THE DESIRED SIDE ONLY.

Consequence & remedy

Consequence: THE DRIVER MAY NOT BE ABLE TO CLEARLY SIGNAL THEIR INTENTIONS TO TURN, CHANGE TRAVEL LANES, OR POTENTIALLY WARN OTHERS OF AN IMPAIRED VEHICLE OPERATING CONDITION INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE SUSPECT FLASHER MODULES WITH A NEW FLASHER MODULE DESIGNED WITH SEALED RELAYS AND MORE DURABLE CONTACT MATERIAL INSIDE OF THE RELAYS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2005. ISUZU BEGAN MAILING OWNER LETTERS ON AUGUST 4, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, GMC AT 1-866-996-9463, ISUZU AT 1-800-255-6727, BUICK AT 1-866-608-8080, AND OLDSMOBILE AT 1-800-630-6537.

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

4

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.

EA07009 · Fuel Pump Module Leaks Gasoline

Opened Jul 10, 2007 · Closed Aug 28, 2008

Status: closed (inferred from source dates) · Fuel System, Gasoline:delivery:fuel Pump

DURING THE COURSE OF THIS EA INVESTIGATION, ODI OBSERVED THAT THE MAJORITY OF THE COMPLAINTS (88%) AND WARRANTY CLAIMS (94%) WERE REPORTED FOR VEHICLES THAT ARE REGISTERED FOR USE IN THE SALT BELT REGION OF THE US.THIS AREA INCLUDES 20 STATES IN THE NORTHEAST, MID ATLANTIC AND THE MIDWEST REGIONS AND THE DISTRICT OF COLUMBIA.CONSUMERS IN THE SALT BELT REGION REPORTED TO ODI THAT THEY COULD SMELL FUEL VAPORS IN THEIR VEHICLES WHILE DRIVING.UPON FURTHER EXAMINATION OF THEIR VEHICLES, THEY DISCOVERED THAT FUEL VAPORS WERE COMING OUT OF THE TOP OF THE FUEL TANK. THIS CONDITION IS CAUSED BY CORROSION OF THE RETURN AND SENDER LINES OF THE FUEL PUMP MODULE.WATER AND ROAD SALT COLLECT ON TOP OF THE FUEL PUMP LEADING TO SMALL PINHOLES APPEARING ON THE FUEL LINES.FUEL MAY LEAK AND COLLECT ON TOP OF THE MODULE AND/OR SPILL ONTO THE GROUND.THE DATA EVALUATED UNDER THIS INVESTIGATION REFLECT A RELATIVELY LOW FREQUENCY OF OCCURRENCE THAT LARGELY ARISES IN SALT BELT STATES.GM HAS EXTENDED THE WARRANTY ON THE SUBJECT COMPONENT TO TEN YEARS OR 120,000 MILES.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME; ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION SELECT DOCUMENT SEARCH.

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.

EA04021 · Brake Lamp Failure

Opened Aug 3, 2004 · Closed Nov 4, 2004

Status: closed (inferred from source dates) · Exterior Lighting:brake Lights

GM STATES THAT SOME BRAKE/TAIL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO MALFUNCTIONING BRAKE/TAIL LAMP SOCKETS.ON MARCH 2, 2004, GM INITIATED A 6-YEAR/72,000 MILE SPECIAL POLICY FOR 989,487 SUBJECT VEHICLES TO INSPECT AND REPLACE THE REAR BRAKE/TAIL LAMP BULB SOCKET ASSEMBLIES.ON APRIL 4, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-032) BASED ON CONSUMER COMPLAINTS ALLEGING BRAKE LIGHTS NOT OPERATING WHEN THE BRAKE PEDAL IS DEPRESSED.ON AUGUST 3, 2004 ODI UPGRADED PE04-032 TO AN ENGINEERING ANALYSIS (EA04-021).BY LETTER DATED OCTOBER 27, 2004 GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA # 04V527) COVERING SUBJECT VEHICLES THAT WERE NOT ALREADY REPAIRED UNDER GM'S SPECIAL POLICY.MY 2004 SUBJECT VEHICLES BUILT AFTER AUGUST 8, 2003 CONTAIN IMPROVED BRAKE LAMP ASSEMBLIES AND ARE NOT INCLUDED IN THE RECALL.GM DEALERS WILL INSTALL THE IMPROVED BRAKE LAMP ASSEMBLY ON SUBJECT VEHICLES BUILT ON AUGUST 8, 2003 AND EARLIER.THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.