Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.


really awful
Crashes / Fires:
0 / 0
Injuries / Deaths:
5 / 0
Average Mileage:
53,928 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2003 GMC Envoy XL fuel system problems

fuel system problem

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2003 GMC Envoy XL Owner Comments

problem #12

Nov 142008

Envoy XL

  • 92,000 miles


The contact owns a 2003 GMC Envoy XL. The contact stated that when adding gasoline to the vehicle, the fuel tank began to leak. The contact stated that he was unable to add fuel to its capacity due to the leak. The vehicle had not been inspected by the dealer. The failure mileage was 92,000 and the current mileage was 105,000.

- Bensalem, PA, USA

problem #11

May 052007

Envoy XL 6-cyl

  • Automatic transmission
  • 56,000 miles
2003 GMC Envoy XL, check engine light on, smell of fuel, and leak when parked on hill. Took vehicle to dealer. It was out of warranty, but replaced fuel tank, $979.11 repair bill. Vehicle had 74,980 miles on it and had problems for approximately 18,000 miles before having it fixed... dealership said nothing about the problem being possibly epidemic.

- Griffin, GA, USA

problem #10

Jan 242007

Envoy XL 6-cyl

  • Automatic transmission
  • 78,000 miles
Gas tank failed. Had to replace at a cost of over $1000 on 2003 GMC Envoy. Have gas tank which failed - was retrieved from dealer when car was pick up if NHTSA is interested. Should not have to replace a gas tank.

- Crownsville, MD, USA

problem #9

Dec 242006

Envoy XL 4WD 6-cyl

  • Automatic transmission
  • 66,700 miles


The plastic gas tank on my 2003 Envoy XL is cracked at the neck going into the tank releasing gas and gas fumes. Gas is leaking from the crack and could cause the vehicle to catch fire and/or explode.

- Blountville, TN, USA

problem #8

Oct 272006

Envoy XL 6-cyl

  • Automatic transmission
  • 48,000 miles
In the past three weeks I have smelled gas and started getting a check engine light did all the necessary steps to correct the problem come to find out the filler neck is broken away from the tank that has a huge potential of a fiery rear-end crash. Cursing the net it seems I am not the only one and from some of the comments have lead me to believe that it is a common problem out there. Is there some way to get GM to fix their problem with their gas tank?

- Mcqueeney, TX, USA

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problem #7

Oct 152006

Envoy XL 6-cyl

  • Automatic transmission
  • 37,000 miles
: the contact stated while driving 35 mph on normal road conditions, the check engine light illuminated, and a warning signal displayed on the vehicle's panel. Also, the contact smelled gas fumes in and around the vehicle. It was taken to a dealership, who determined that the fuel tank had a leak; the filler neck was detached from the tank. The fuel tank was replaced which corrected the problem. Updated 12/1/2006 - the filler neck did not connect properly to the tank which was found when the tank pressurized. The consumer fells that the connection of the neck and tank is a design flaw.

- Clarkesville, GA, USA

problem #6

Oct 062006

Envoy XL

  • Automatic transmission
  • 76,277 miles


: the contact stated while driving 5 mph during normal road conditions in a school zone, the gas light illuminated and a gas odor fumigated the vehicle. It was taken to the dealer, who determined that there was a crack in the gas tank which leaked vapors and the gas tank needed to be replaced. No repairs were made. Updated 12/01/06.

- Bishopville, SC, USA

problem #5

Mar 212006

Envoy XL 4WD 6-cyl

  • Automatic transmission
  • 60,000 miles
Service engine soon light came on, small emissions fuel leak, dealership wanted to replace fuel tank, obvious design flaw, hoping for recall.

- Clarkston, MI, USA

problem #4

Aug 152005

Envoy XL

  • Automatic transmission
  • 42,659 miles
2003 GMC Envoy XL. The gas tank cracked where the hose was connected to the gas tank. Took vehicle to mechanic after the check engine light came on and they said not to fill up more than half way. The fumes could cause an explosion. Dealer had to order the tank. Called manufacturer and they said there was no recall. This vehicle has not been in any accidents to cause this problem.

- Douglasville, GA, USA

problem #3

Feb 072003

Envoy XL 6-cyl

  • Automatic transmission
  • 500 miles
The 2003 Envoy we purchased gave us numerous problems, including a number of the ones other owners mentioned here, like the glass liftgate that does not operate properly, various electrical problems, but especially the outside rear view mirrors that move on their own no matter how many times they were supposedly fixed by service technicians. They do not stay in the position we set them in, and the fuel tank leaking is very dangerous as well as inhaling freon because of malfunctioning A/C system. Why is GMC doing nothing to solve these problems" I can't understand how they are getting away with this seeing that so many owners are having the same problems. What do we have to do to get some help"

- Ashland, AL, USA

problem #2

Nov 252000

Envoy XL 6-cyl

  • Automatic transmission
  • 47,000 miles
I was stopped at a drive up atm and the check engine light came on. I called onstar and theyasked that I check the gas cap which I did. Later that day while parked on a sloping driveway for an hour I found gasoline leaked and covered the driveway. The cause was a crack in the gas tank just below the filler neck. I was out of the state; my son's mechanic said that I can drive home as long as the tank is less than half full. No prior repair on the fuel tank or required its removal. I called GMC andwas told that there was no recall but the person (tracy) that I spoke to said that this has occured to a number of vehicles GMC Envoy XL 2003. My dealer even stocks the fuel tanks for the vehicle.

- Okatie, SC, USA

problem #1

Oct 022004

Envoy XL 6-cyl

  • Automatic transmission
  • 43,000 miles
Our 2003 GMC enovy XL has just had the gas tank replaced again due to cracking of the plastic tank. This obvious design flaw is happening between the fuel tank neck and the fuel tank. The engine check light came on and there was a gas smell. The vehicle wasn't accelerating as it should.

- Seguin, TX, USA

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