2004 GMC Envoy XL Problems
- Complaints
- 187filed with NHTSA
- Median mileage
- 66,379miles, 144 complaints with mileage
- Recalls
- 1campaigns on record
- Trend
- RisingComplaints filed in the last 3 full calendar years are at least 25% higher than in the 3 years before.
- NHTSA crash rating
- —overall rating starts with 2011 models
- EPA fuel economy
- 16 mpgcombined, 5.3L 8-cyl RWD · 14 city / 18 hwy
Sources: NHTSA records for the 2004 GMC Envoy XL (complaints, recalls, investigations), EPA fuel economy. Report an error
What owners report
Owners of the 2004 GMC Envoy XL most often describe instrument cluster problems: the speedometer and other gauges jump, stick, or stop working, usually appearing around the 50,000-80,000 mile range. A second cluster of complaints concerns fuel tank cracks and leaks that trigger the check engine light, and a smaller group describes harsh or failed transmissions.
- Electrical system
Erratic or dead speedometer and gauges (instrument cluster)
- 70 complaints (37%)
- median 64,328 mi at 5.3 yrs old (55 state mileage)
- owner-quoted repair $500 (median of 13 quotes)
- filed 2006–2015
Owners describe the speedometer reading wildly high or low, sticking at a fixed speed, or sitting at zero while driving, sometimes with the tachometer, fuel, oil and temperature gauges failing alongside it. In some accounts the gauges sweep and warning lights stay lit after startup. Dealers typically diagnosed a failed instrument cluster and quoted several hundred dollars for parts and labor, and some owners say they were told the part is commonly replaced on these vehicles. Mostly reported between roughly 30,000 and 80,000 miles, with many appearing shortly after the basic warranty ended.
What to check: Start the vehicle and watch every gauge through a short drive, including at a stop; ask whether the instrument cluster has been replaced and keep a GPS speed reading as a cross-check.
2 excerpts from owner complaints in NHTSA records
“Speedometer doesn't work. It will jump around and stick on any given speed and remain there. Sometimes when the vehicle is restarted it will decrease 5 MPH from the point at which it was last positioned. I cannot regulate my speed without the speedometer and afraid that I will cause an accident. It has not been fixed.”
NHTSA complaint #10179250, filed 2007-01, 50,000 miles“My car's speedometer started to give me the wrong speed and eventually just quit and is now stuck on 0. A little while after, the radiator gauge does not work either. It seems that the instrument cluster is slowing going out. We haven't fixed the instrument cluster yet because we have been trying to talk with the dealer and Gmc about the problem, but they refused to fix it because we were just one person.”
NHTSA complaint #10297446, filed 2009-12, 90,000 miles - Fuel system
Cracked fuel tank / fuel filler neck leak
- 19 complaints (10%)
- median 93,000 mi at 6.8 yrs old (17 state mileage)
- filed 2007–2017
Owners describe the check engine light coming on and being told the plastic fuel tank, often at the filler neck, was cracked and leaking fuel or vapor. Several say the tank must be replaced as a complete assembly, and some report a special coverage policy exists for this condition while others say their vehicle was not covered. Dealers and mechanics advised against filling the tank completely in some cases. Reported from about 10,000 miles upward, with many between 60,000 and 130,000 miles.
What to check: Look for a fuel smell around the filler neck and under the rear of the truck, and ask whether the tank has been replaced or the check engine light diagnosed for an EVAP leak.
2 excerpts from owner complaints in NHTSA records
“My Gmc's service engine soon light went on and I took into the shop. They stated that there is a fuel issue for the fuel cap and that the fuel tank needs to be replaced because it leaks. This is a manufacturers defect and this part should never wear out over time or due to the number of miles driven. Gmc needs to stand behind their vehicle and replace this part for free!”
NHTSA complaint #10526242, filed 2013-07, 160,021 miles“2004 Gmc envoy leaking gasoline. I was told my car was leaking gasoline. I contacted Gmc corp. Office to request assistance for the repair and was denied, reason given local service provider said consumer caused crack in gas tank. Also asked for assistance at least a percentage off from local dealership also denied. I called the local service repair while on hold with Gmc and was told they did not tell Gmc that I caused the damage. The local service repairman said they can not determine how the damage was caused. …”
NHTSA complaint #10394324, filed 2011-04, 100,000 miles - Transmission and drivetrain
Harsh shifting or transmission failure
- 10 complaints (5%)
- median 68,000 mi at 6.0 yrs old (9 state mileage, few)
- filed 2004–2019
Owners report hard jerks on the 2nd gear shift or when engaging drive, and in more severe cases a loud noise followed by loss of first gear and reverse or the vehicle moving in the wrong direction for the selected gear. Some were told the transmission needed replacement, while others say the dealer could not find a fault. Reported from a few thousand miles up to about 160,000 miles, with several cases under 70,000 miles.
What to check: Test drive from cold and note any clunk or delay going into drive and second gear, and check whether the transmission has been serviced or replaced.
2 excerpts from owner complaints in NHTSA records
“Upon shifting tranny into park gear vhecile continued to roll forward or backward note : upon pushing in shifter relaese button shifter engaed in park gear however indicator displayed drive internal failure cable broken and emergency brake did not work so I had my neigbor put bricks behind the rear wheels all the while the car shut itself off and the steering wheel locked”
NHTSA complaint #10544194, filed 2013-09, 132,193 miles“I was driving back home and parked in my driveway put the vehicle in parked and when I released the brake peddle the vehicle jump and took off in reverse. I missed hitting my wife by inches. I then stopped the vehicle and turned it off. Then I tried to restart the vehicle and it would not start. I tired to push the button on the shifter. I then though there was something wrong with the transmission. I then when to the internet and search what would cause the problem. Finding it was something to do with the lockout devise. …”
NHTSA complaint #10522172, filed 2013-06, 62,000 miles
Buying note. Have a pre-purchase inspection focus on the instrument cluster, fuel tank and filler neck, and transmission behavior, since these are the areas owners most often describe. Service records showing cluster or tank replacement are worth asking for.
Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.
NHTSA recorded 187 consumer complaints for the 2004 GMC Envoy XL. 144 of the complaints include a mileage, and 26% of those were filed for vehicles with under 50,000 miles; the median is 66,379 miles. Of all complaints, 6 involved a crash, 6 a fire, 8 an injury, according to the filers. NHTSA lists 1 recall campaign and 108 technical service bulletins for this model year.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Electrical system81 43%
- Fuel system28 15%
- Engine cooling15 8.0%
- Exterior lighting11 5.9%
- Vehicle speed control9 4.8%
- Air bags7 3.7%
- Brakes6 3.2%
- Engine5 2.7%
Also reported: Equipment (5), Body and structure (5), Tires (5), Seats (4), Other or unknown (3), Seat belts (3), Steering (3), Latches, locks and linkages (2), Interior lighting (1), Suspension (1).
Example complaints
Electrical system: “I picked up my kids and niece from school and was visiting at my brothers house for a few hours (3 to be exact) when my kids and I went to leave my rear window was shattered. I filed a police report and the officer could not see any reason for my window to shatter like it did.”
NHTSA complaint #10670900, filed 2015-01, 139,000 milesFuel system: “Own a 2004 Gmc envoy and I have problems with the fuel gauge and the odometer. The fuel gauge goes past the f line when the vehicle is not on fuel. Also the odometer will stop working or get stuck on 10-15 MPH. He happens often...every other day. I was told that it would cost 1400 to fix and a possibility it may not fix the problem.”
NHTSA complaint #10405702, filed 2011-06, 95,000 milesTransmission and drivetrain: “As I was driving in cruise control speed off 55 MPH vehicle begin to make a dragging sound. After stopping and placing vehicle into park and then putting gear back into drive vehicle began to go into reverse mode. I then tried every other gear 1,2,3 drive the vehicle continued to still go into reverse. The car still turns on without a problem but will not move forward when in drive.”
NHTSA complaint #10701199, filed 2015-03, 159,000 milesEngine cooling: “I purchased a 2004 envoy with 18,000 miles in the summer of 2006. Beginning in january 2007, my 3 year old son let me know that he was cold while riding in the back seat and begged that I turn off the air. Turns out that the vent in the back of the car was blowing ice cold air on my son. The temperature outside was approximately 10 degrees. I called and scheduled a time to take my car into the dealership, as it was still under warranty. …”
NHTSA complaint #10182174, filed 2007-02, 33,000 milesMileage when problems were reported
26% of the 144 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 48,000 and 100,000 miles.
Complaints by year filed
Trend: rising. Complaints filed in the last 3 full calendar years are at least 25% higher than in the 3 years before.
Fuel economy and running cost
EPA ratings for each 2004 GMC Envoy XL version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).
| Version | Engine | Transmission | City | Hwy | Comb. | Fuel / yr |
|---|---|---|---|---|---|---|
| Envoy XL 2WD | 4.2L 6-cyl | 4-speed automatic | 13 | 18 | 15 | $4,450 |
| Envoy XL 2WD | 5.3L 8-cyl | 4-speed automatic | 14 | 18 | 16 | $4,200 |
| Envoy XL 4WD | 4.2L 6-cyl | 4-speed automatic | 13 | 18 | 15 | $4,450 |
| Envoy XL 4WD | 5.3L 8-cyl | 4-speed automatic | 13 | 17 | 15 | $4,450 |
Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.
Recalls and investigations
- 04V527000Nov 1, 2004Exterior lighting › Brake lightsCovers: GMC Envoy XL 2002–2004, Oldsmobile Bravada 2002–2004, Chevrolet Trailblazer 2002–2004 +2 more
On certain sport utility vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative.
Recall details for the 2004 GMC Envoy XL → · Check a VIN at nhtsa.gov/recalls
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 108 on record; the latest 10 are shown.
- 11020816Jul 18, 2025Other or unknown. This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
- 11007208Sep 6, 2024Other or unknown. This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires…
- 11006621Aug 26, 2024Electrical system. Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need…
- 11006421Jul 24, 2024Transmission and drivetrain. GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging…
- 11004761Jun 28, 2024Engine, Fuel system. This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with…
- 11004557Jun 17, 2024Other or unknown. This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 11002312Jun 6, 2024Electrical system. This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492…
- 11000576May 7, 2024Other or unknown. This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal…
- 10252735Mar 28, 2024Electrical system. This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish.
- 10251887Mar 14, 2024Engine cooling. This bulletin advises the technician of possible location of an internal coolant leak from a specific cylinder head and location.
Other model years of the GMC Envoy XL
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2006 | 109 | 60,062 | 5 | — | 16 | Not compared (before 2008) | Stable |
| 2004 | 187 | 66,379 | 1 | — | 16 | Not compared (before 2008) | Rising |
| 2003 | 228 | 79,400 | 3 | — | 16 | Not compared (before 2008) | Falling |
| 2002 | 70 | 65,000 | 3 | — | 16 | Not compared (before 2008) | Stable |
All GMC Envoy XL model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 2004 GMC Envoy XL?
Owners of the 2004 GMC Envoy XL most often describe instrument cluster problems: the speedometer and other gauges jump, stick, or stop working, usually appearing around the 50,000-80,000 mile range. The issues reported most often: Erratic or dead speedometer and gauges (instrument cluster); Cracked fuel tank / fuel filler neck leak; Harsh shifting or transmission failure.
How many NHTSA complaints does the 2004 GMC Envoy XL have?
NHTSA recorded 187 consumer complaints for the 2004 GMC Envoy XL as of Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2004 GMC Envoy XL is reported most often?
Electrical system is named most often, in 81 complaints (43% of the total), followed by fuel system with 28.
Has the 2004 GMC Envoy XL been recalled?
NHTSA lists 1 recall campaign for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
What gas mileage does the 2004 GMC Envoy XL get?
The EPA rates the 2004 GMC Envoy XL (Envoy XL 2WD, 5.3L 8-cyl) at 16 mpg combined, 14 city and 18 highway, with an estimated annual fuel cost of $4,200 at 15,000 miles a year. Other engine and drive versions are rated differently.
At what mileage are problems with the 2004 GMC Envoy XL reported?
Among the 144 complaints that include a mileage, the median is 66,379 miles and the middle half falls between 48,000 and 100,000 miles; 26% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Fuel economy is from the EPA and DOE (fueleconomy.gov).
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.