2004 GMC Envoy Problems

What owners report

Owners of this model year most often describe failures of the instrument cluster: the speedometer, fuel gauge, oil pressure and tachometer needles stop working, stick at the wrong value or read erratically. Many complaints add a fuel-system theme — a strong gas smell, an EVAP-related check engine light, and cracks around the fuel filler neck or tank. Problems are reported from relatively low mileage upward, and most complaints describe gradual or intermittent onset rather than a single event.

1. 1
   Electrical system

   Instrument cluster gauges fail or read wrong

   • 145 complaints (40%)
   • median 63,470 mi at 5.6 yrs old (122 state mileage)
   • 2 mention a crash, fire or injury
   • owner-quoted repair $500 (median of 21 quotes)
   • filed 2006–2022

   Speedometer, fuel gauge, tachometer, oil pressure and battery gauges stop working, stick at a fixed value or swing to incorrect readings, often one after another. The fuel gauge may show a quarter tank and then empty on the next start, and the speedometer can read zero or peg high while driving. Owners describe dealers quoting several hundred dollars for a replacement cluster or diagnosis, and complaints note that no recall covers this on the Envoy even though other GM models used a similar cluster. Reported from as low as roughly 30,000 miles and commonly in the 45,000–100,000 mile range, with intermittent on-and-off behavior.

   What to check: Start the vehicle and watch every gauge through a short drive: confirm the speedometer tracks actual speed and the fuel gauge moves when the tank level changes. Ask whether the cluster has ever been replaced and keep records if it has.

   2 excerpts from owner complaints in NHTSA records

   “I purchased a 2004 Envoy off the showroom floor. First issue was an erratic speedometer, then non-working gas gauge, now it is all gauges. I have a picture with the car in park showing 15 MPH, the digital reading shows a full tank of gas but the gauge needle is below empty and also no oil pressure or temperature. The entire cluster is faulty, not just one gauge.”

   NHTSA complaint #10304829, filed 2010-02, 53,000 miles

   “Speedometer on 2004 Gmc Envoy slt quit working. I found that this is a very common problem with GM vehicles, however they have not issued a recall for it. I feel that this could be a huge safety issue and that they are aware of it but continue to ignore complaints. Knowing your speed is extremely important when driving.”

   NHTSA complaint #10293911, filed 2009-11, 73,000 miles
2. 2
   Fuel system

   Fuel smell, EVAP leaks and cracks at the filler neck/tank

   • 60 complaints (16%)
   • median 107,300 mi at 9.9 yrs old (49 state mileage)
   • 5 mention a crash, fire or injury
   • owner-quoted repair $1,107 (median of 6 quotes)
   • filed 2007–2025

   Owners report a strong gasoline smell inside and outside the vehicle, sometimes along with a check engine light and P0455 or P0442 EVAP codes. Several describe fuel burping back out of the filler neck during refueling, fuel visible around the filler area, or a cracked filler neck or tank that leaks fuel and vapors. Repairs mentioned include replacing the fuel cap, purge valve, charcoal canister or the fuel tank itself, and some owners say the problem returned after a used tank was installed. Mostly reported between about 100,000 and 190,000 miles; some owners note the smell is noticeable at any speed.

   3 related service bulletins

   What to check: Smell for fuel around the filler neck and under the vehicle after a fill-up, and check for a stored EVAP code. Ask whether the fuel tank or filler neck has been replaced and whether an EVAP smoke test was done.

   2 excerpts from owner complaints in NHTSA records

   “I just had my brakes serviced and my bushings changed, but my ABS light still comes on. Also when I go to brake the car starts to shake and I'm going the speed limit. The engine has a rough idle, and shuts off when at a complete stop and when the vehicle is in motion. I've had many things replaced on the vehicle, such as purge valve, gas cap. Charcoal canister and fuel tank. In the engine the spark plugs were changed as well as the coil packs and the fuel injectors. Along with the camshaft sensor. Still getting p0455 and po0014. …”

   NHTSA complaint #11311534, filed 2020-02, 225,000 miles

   “2004 Gmc Envoy 6-cyl 2wd with ~172,000 miles. Check engine light was due to evap leak in the fuel system. Smoke check at the mechanics resulted in visible smoke exiting the filler neck of the fuel tank (not the filler neck from the gas line). New fuel tank (dealer part only!) is ~$900 from dealer to dealer. Plus labor.”

   NHTSA complaint #10361075, filed 2010-10, 172,000 miles
3. 3
   Exterior lighting

   Headlights and exterior lamps quit or flicker

   • 37 complaints (10%)
   • median 89,673 mi at 9.0 yrs old (25 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2004–2022

   Complaints describe low beams that stop working and later come back, headlights that flicker or dim while driving, and lamps that stay on after being switched off. One owner found the headlight socket melted with smoke from under the hood, and others note that headlight flicker made oncoming drivers think they were being flashed. Dealers reportedly could not find the cause in some cases. Spread across the range from about 45,000 to 160,000 miles, often described as intermittent.

   Recall 05V1980003 related service bulletins

   What to check: Check both low and high beams, turn signals and running lights with the engine running, and look at the headlight connectors for melting or discoloration. Ask whether lamp sockets or switches have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “2004 Gmc Envoy, headlights flickered while driving. Oncoming traffic thought I was flashing at them, causing them to pull over or flash me back, safety hazard. Took car twice to dealership, but they failed to find the cause of the problem. E found on online forums where many people have similar problem with no answers.”

   NHTSA complaint #10186363, filed 2007-03, 45,000 miles

   “Noticed smoke coming from under the hood and then passenger side head light went out. Upon investigation I noticed the light socket for the head light was melted. I did some research and learned that this appears to be a very common problem, with some actually causing fire or accidents.”

   NHTSA complaint #10548112, filed 2013-10, 86,000 miles
4. 4
   Air bags

   Airbags did not deploy in a collision

   • 25 complaints (7%)
   • median 62,750 mi at 6.2 yrs old (20 state mileage)
   • 18 mention a crash, fire or injury
   • filed 2005–2020

   Owners describe frontal or side impacts in which the airbags did not deploy, including a head-on collision and a rollover. Some complaints also mention seat belt burns or injuries from the crash. The reports generally describe the crash circumstances rather than a diagnosis, and in most cases the airbag system was not inspected or repaired afterward according to the complaint. Reported at a wide mileage range, from about 29,000 to 160,000 miles, in crash situations rather than routine driving.

   What to check: Ask whether the airbag warning lamp works and goes out after the bulb-check cycle, and whether the vehicle has any unrepaired collision history. A pre-purchase scan for stored airbag codes and a visual check of the front sensors is worthwhile.

   2 excerpts from owner complaints in NHTSA records

   “While traveling down I-95 at appx. 60mph the car in front of me stopped short. I slammed into the back of it. My airbags did not deploy, nor did onstar call to check on me (so much for believing in those ads!) the entire front end needs to be replaced. Fluids were spilling from the vehicle. 2 witnesses are capitol hill police officers who were shocked that the airbags did not deploy. The seatbelt did restrain me causing irritation at that site. My back, neck and head were aching. I was checked out by the er.”

   NHTSA complaint #10286793, filed 2009-10, 101,854 miles

   “Dt: consumer states that she was in a head on collision on july 8, 2005 and the air bags did not deploy. She was going 55 MPH when hit. There was damage to the vehicle and a police report was taken. Consumer states she has neck and back injuries, she is going to the doctor for a follow up visit today. Her daughter has seat belt burns on her neck. The vehicle is currently being inspected by the insurance company; it had to be towed to a body shop. …”

   NHTSA complaint #10128270, filed 2005-07, 38,000 miles
5. 5
   Engine

   Engine stalls, rough idle or loses power

   • 20 complaints (5%)
   • median 75,000 mi at 6.5 yrs old (17 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2005–2023

   Owners describe the engine stalling without warning at various speeds and restarting normally afterward, plus rough idle, hesitation on acceleration and, in a few cases, a shaking engine with a rattling noise that led to an engine replacement. Repairs mentioned include spark plugs and fuel-system cleaning, and in some complaints the problem returned after the repair. Mostly reported above about 75,000 miles, with several cases in the 120,000–150,000 mile range.

   3 related service bulletins

   What to check: Let the engine idle and listen for rough running or misfire, and ask for any stored engine codes. Ask about the service history for plugs, coils and fuel-system cleaning if the engine has ever stalled.

   2 excerpts from owner complaints in NHTSA records

   “Vehicle was being driving approximately at 55 MPH. Engine loss power, gas pedal lost resistance and went all the way down to the floor board. Vehicle was pulled over to the side of the road and engine was stalled and all the dash lights were flashing one and off. Engine started to have white smoke coming from under the hood. After a few minutes, the white smoke turned into black smoke and the engine caught on fire. Vehicle was engulfed in flames after a few minutes.”

   NHTSA complaint #10871973, filed 2016-06, 128,000 miles

   “The contact owns a 2004 Gmc Envoy. While driving various speeds, the vehicle would stall without warning. The vehicle would operate normally once the engine was restarted. The dealer stated that the spark plugs were faulty. The vehicle was repaired, but the failure recurred. The manufacturer was not notified. The failure mileage was 146,000. Updated 8/27/14 updated 8/29/2014”

   NHTSA complaint #10610348, filed 2014-07, 146,000 miles

Buying note. On a used example, spend time with the gauges and lamps before anything else, since cluster and lighting faults are the most frequent complaints and can be costly to put right. Also check for fuel odors around the filler neck and ask for service records on the fuel tank, EVAP system and any engine-stall repairs.

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.