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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 →

When problems were reported

Mileage at the reported incident

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 reports
48,000 miles · Jun 14, 2011
Fuel System, Other

2005 GMC ENVOY FUEL GAUGE SENSOR. VEHICLE HAS 48,000 MILES AND WHEN I FILL UP THE GAS TANK THE FUEL GAUGE GOES UP AND DOWN AND STAYS AT EMPTY WITH THE LIGHT FLASHING. I NEVER KNOW HOW MUCH FUEL IS IN THE VEHICLE. *TR

NHTSA ODI #10406820

34,000 miles · Jun 14, 2011
Power Train

TL* THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT WAS DRIVING 30 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING AND WOULD NOT RESTART. THE VEHICLE WAS THEN TOWED TO A LOCAL MECHANIC WHO INSPECTED THE VEHICLE AND INFORMED THE CONTACT THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE TRANSMISSION WAS REPLACED AT THE CONTACT'S EXPEN…

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TL* THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT WAS DRIVING 30 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING AND WOULD NOT RESTART. THE VEHICLE WAS THEN TOWED TO A LOCAL MECHANIC WHO INSPECTED THE VEHICLE AND INFORMED THE CONTACT THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE TRANSMISSION WAS REPLACED AT THE CONTACT'S EXPENSE. A LETTER WAS SENT TO THE MANUFACTURER WHO IN RETURN, CALLED THE CONTACT AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 34,000. UPDATED 07/08/11 *BF UPDATED 07/18/11

NHTSA ODI #10406791

64,950 miles · Jun 8, 2011
Fuel System, Gasoline

2005 GMC ENVOY GAS GAUGE READS EMPTY WHEN RECENTLY FILLED UP AND CONSTANTLY FLUCTUATES UP AND DOWN. APPARENTLY THE FUEL TANK LEVEL SENSOR IS DEFECTIVE AND COULD RESULT IN THE VEHICLE UNKNOWINGLY RUNNING OUT OF FUEL, STALLING AND BEING REAR ENDED BY ANOTHER VEHICLE. *TR

NHTSA ODI #10405541

92,000 miles · Jun 6, 2011
Fuel System, Gasoline

TL*THE CONTACT OWNS A 2005 GMC ENVOY. WHILE THE VEHICLE WAS PARKED A WARNING SOUND BEGAN TO INDICATE TO THE CONTACT THAT THE FUEL TANK WAS EMPTY AND THE FUEL GAUGE READING INDICATED THAT THE FUEL TANK WAS EMPTY. THE CONTACT STATED THE FUEL WAS ADDED TO THE VEHICLE BEFORE THE FAILURE OCCURRED. THE FUEL INDICATOR ALSO DISPLAYED…

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TL*THE CONTACT OWNS A 2005 GMC ENVOY. WHILE THE VEHICLE WAS PARKED A WARNING SOUND BEGAN TO INDICATE TO THE CONTACT THAT THE FUEL TANK WAS EMPTY AND THE FUEL GAUGE READING INDICATED THAT THE FUEL TANK WAS EMPTY. THE CONTACT STATED THE FUEL WAS ADDED TO THE VEHICLE BEFORE THE FAILURE OCCURRED. THE FUEL INDICATOR ALSO DISPLAYED A READING THAT FLUCTUATES AND DOES NOT SHOW THE ACCURATE AMOUNT OF FUEL IN THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE DEALER WAS CONTACTED AND STATED THE FUEL LEVEL SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THERE WAS AN INVESTIGATION UNDER NHTSA ACTION NUMBER: DP10001 (FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM). THE APPROXIMATE FAILURE MILEAGE WAS 92,000.

NHTSA ODI #10405326

127,197 miles · Jun 5, 2011
Fuel System, Other

I HAVE A 2005 ENVOY AND IT JUST STARTED SMELLING OF GAS FUMES REALLY BAD AND AS I WAS READING SOME INFORMATION ON YOUR SITE I HAVE ALSO AGREE IT IS A MANUFACTURING PROBLEM YOU SEE WHERE IT WAS SEALED NOT BY OIL CLAY OR ANY GOOEY SUBSTANCE OF THAT SOURCE ITS SECURED BY WELDING I KNOW THIS BECAUSE I WORK FOR NUMMI AND I WAS A QC I…

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I HAVE A 2005 ENVOY AND IT JUST STARTED SMELLING OF GAS FUMES REALLY BAD AND AS I WAS READING SOME INFORMATION ON YOUR SITE I HAVE ALSO AGREE IT IS A MANUFACTURING PROBLEM YOU SEE WHERE IT WAS SEALED NOT BY OIL CLAY OR ANY GOOEY SUBSTANCE OF THAT SOURCE ITS SECURED BY WELDING I KNOW THIS BECAUSE I WORK FOR NUMMI AND I WAS A QC INSPECTOR AND DID THE TEAR DOWN ON THE GAS TANKS FOR SAFETY IT SOUNDS LIKE SOME TANKS SLIP BY BECAUSE NOT EVERY ONE IS CK THERE RANDOM CHECKS I BELIEVE ITS THE O YES O RING THAT WAS NOT PROPERLY WELDED PROPERLY CAUSING LEAKS THAT IS THE GAS FUME I AM SMELLING IN MY CURRENT ENVOY (2005) .AND YES IT IS A SAFETY ISSUE PEOPLE CAN DIE FROM THESE FUMES YOU KNOW IT AND SO DUE I .LET ME TELL YOU ABOUT WHAT HAD HAPPEN ONE DAY THERE WAS THIS GENTLEMAN WHO WAS ON THE JOB AND LOTS OF GAS TANK SLIP THROUGH THAT DAY ROLLING OFF THE ASSEMBLY LINE AND SHIP OUT TO DEALER SHIPS WHERE THE O RINGS WERE NOT HOLDING UP DURING THE TEAR DOWN PROCESS OF THE INSPECTION. WELL NEED LESS TO SAY THE UNITS WENT OUT TO BE SOLD TO CONSUMER .AND THEY WANTED TO FIRE THE INSPECTOR BUT THEY JUST SUSPENDED HIM FOR A WEEK.ANOTHER PROBLEM OCCURRED ON MY INSPECTION ROUTE IN BODY N WELD I HAD FOUND A SPLIT ON THE FLOOR PAN OF THE COROLLA VERY LARGE AND HARD TO SEE GUESS I JUST GOT LUCKY BUT SO THE MANAGER AT THAT TIME WAS A FEMALE AND SHE WENT TO THE END OF THE ASSEMBLY LINE AND SURE ENOUGH THOSE SPLIT HAD BEEN SHIP OUT TO THE DEALER SHIPS THEY TURN A BLIND EYE TO THE ONES THAT WERE SHIP YOU SEE IF YOU KNOW NOTHING ABOUT MEDAL IT WILL CONTINUE TO SPLIT OF COURSE THE CARPET COVER IT WHO WILL KNOW .THE REMINDING ONES WELL THEY PLACE A SPOT WELD ON EACH SIDE OF THE SPLIT AND SOME SEALER. WITH THAT SAID I CERTAINLY BELIEVE THE MANUFACTURE IS CERTAINLY RESPONSIBLE AND PAY FOR THESE REPAIRS NO MATTER THE MILEAGE OR THE YEAR. BY THE WAY I WORK IN THE BODY-N-WELD SHOP. IT IS NOT A WARE AND TEAR ISSUE. *TR

NHTSA ODI #10404542

96,000 miles · May 27, 2011
Fuel System, Gasoline

I HAVE A 2005 GMC ENVOY AND THE GAS LIGHT AND FUEL TANK GAUGE ARE MALFUNCTIONING. WHEN WE FILL UP WITH GAS THE EMPTY GAS REMAINS ON FOR SEVERAL MINUTES AND THEN ONLY MOVES TO 1/4 OF A FULL TANK. LATER IT WILL MOVE UP, BUT WILL DRIVING IT WILL JUST DROP TO EMPTY. *TR

NHTSA ODI #10403612

19,000 miles · May 12, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT STATED THAT THE FUEL GAUGE FAILED. THE CONTACT RAN OUT OF GAS WHILE THE FUEL GAUGE DISPLAYED INACCURATELY THAT THE FUEL TANK WAS HALF FULL BUT WAS ACTUALLY EMPTY. THE CONTACTS MECHANIC INSPECTED THE VEHICLE AND ADVISED THAT THE TANK AND SENSOR WOULD NEED TO BE REPLACED. THE VEHI…

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TL* THE CONTACT OWNS A 2005 GMC ENVOY. THE CONTACT STATED THAT THE FUEL GAUGE FAILED. THE CONTACT RAN OUT OF GAS WHILE THE FUEL GAUGE DISPLAYED INACCURATELY THAT THE FUEL TANK WAS HALF FULL BUT WAS ACTUALLY EMPTY. THE CONTACTS MECHANIC INSPECTED THE VEHICLE AND ADVISED THAT THE TANK AND SENSOR WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 19,000 AND THE CURRENT MILEAGE WAS 31,000.

NHTSA ODI #10400680

88,000 miles · May 10, 2011
Fuel System, Other

ON REGULAR BASIS WOULD ADD 10 GALLONS PER FILL UP, THEN DURING A LONG TRIP FILLED THE TANK COMPLETELY: WHICH THEN THE FUEL GAUGE SHOWED EMPTY. THEN WENT UP TO ABOUT HALF. NOW AFTER 10 GAL. FILL THE GAUGE READ EMPTY OR ABOUT 1/4. HAVE NOT NONE MUCH AFTER LEARNING THIS IS A VERY COMMON GM PROBLEM. FIRST TIME IN MY LIFE (DRIVING…

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ON REGULAR BASIS WOULD ADD 10 GALLONS PER FILL UP, THEN DURING A LONG TRIP FILLED THE TANK COMPLETELY: WHICH THEN THE FUEL GAUGE SHOWED EMPTY. THEN WENT UP TO ABOUT HALF. NOW AFTER 10 GAL. FILL THE GAUGE READ EMPTY OR ABOUT 1/4. HAVE NOT NONE MUCH AFTER LEARNING THIS IS A VERY COMMON GM PROBLEM. FIRST TIME IN MY LIFE (DRIVING 27 YEARS) RAN OUT OF GAS RIGHT IN THE MIDDLE OF A BUSY 4WAY INTERSECTION, HONEST TRUTH. DO NOT WANT TO HAVE MY FAMILY IN CAR AFTER THIS INCIDENT. *TR

NHTSA ODI #10399873

Mileage unknown · May 10, 2011
Fuel System, Gasoline

THE GAS GAUGE IS MALFUNCTIONING IN MY 2005 GMC ENVOY (VIN # [XXX]) WHEREAS IT DOES NOT REGISTER THE CORRECT AMOUNT OF GASOLINE.....I CAN FILL IT COMPLETELY UP AND IT WILL SHOW PAST THE EMPTY MARK AND OTHER TIMES IT WILL SHOW 1/4 TANK RIGHT AFTER I FILL UP. I HAVE RAN OUT OF GAS 3X (FORTUNATELY NOT ON A BUSY THOROUGHFARE), BUT T…

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THE GAS GAUGE IS MALFUNCTIONING IN MY 2005 GMC ENVOY (VIN # [XXX]) WHEREAS IT DOES NOT REGISTER THE CORRECT AMOUNT OF GASOLINE.....I CAN FILL IT COMPLETELY UP AND IT WILL SHOW PAST THE EMPTY MARK AND OTHER TIMES IT WILL SHOW 1/4 TANK RIGHT AFTER I FILL UP. I HAVE RAN OUT OF GAS 3X (FORTUNATELY NOT ON A BUSY THOROUGHFARE), BUT THIS CAN BE EXTREMELY DANGEROUS NOT EVER KNOWING FOR CERTAIN HOW MUCH GAS I HAVE IN MY TANK OR NOT. IT IS SO ANNOYING AND FRUSTRATING AND NOT ONLY THAT BUT MY GAS GAUGE 'DINGS' OFF AND ON ALL THE TIME INDICATING THAT I AM LOW ON FUEL EVEN AFTER I HAVE FILLED THE VEHICLE UP. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).*TR

NHTSA ODI #10399807

40,631 miles · May 9, 2011
Fuel System, Gasoline

A FUEL GAUGE STOPPED WORKING. I HAD TO PAY TO HAVE THE GMC DEALER REPLACE THE FUEL LEVEL SENSOR.

NHTSA ODI #10400363

Official recalls

2

06V417000 · 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

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.

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.