hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
75,232 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.

2004 GMC Envoy XL fuel system problems

fuel system problem

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2004 GMC Envoy XL Owner Comments

problem #15

Feb 112014

Envoy XL 6-cyl

  • 133,260 miles


Special coverage adjustment fuel tank inlet check valve fracture #07099A. Issued August 24, 2007. My 2004 GMC Envoy is now experiencing this problem. I was never notified of this as GM claims they did not know I was the owner of this car. I bought it used in 2005. I was told by a mechanic when I took it in to check out the problem that I should not fill the gas tank full as it could cause gas leakage. I am also facing an expensive bill to get this fixed. A recall was never issued and it appears this is a life safety issue. I would appreciate your attention in this matter.

- Princeville, IL, USA

problem #14

May 232012

Envoy XL 6-cyl

  • 125,000 miles
The fuel tank neck where the fuel goes into the vehicle, then down to the gas tank, has in the plastic & leaks fuel & gas vapors so the check engine light is always on. My mechanic said there is no way to fix this without purchasing a new fuel tank since this is all one piece.

- Mundelein, IL, USA

problem #13

Feb 192012

Envoy XL

  • 70,000 miles
The contact owns a 2004 GMC Envoy XL. While parked, the contact noticed a strong gasoline fuel smell. The vehicle was taken to an independent mechanic for diagnostic testing where the mechanic advised the contact that the fuel tank was corroded and fuel was leaking. The vehicle was not repaired. The approximate failure mileage was 70,000.

- San Sebastian, PR, USA

problem #12

Aug 022010

Envoy XL 6-cyl

  • miles


The gas tank or hose is leaking. This is only 7 years old and it is going to be very expensive to fix an feel this should be a recall. Several people have told me that they have had recalls on trailblazers for just this reason.

- Hollis, ME, USA

problem #11

Jun 082011

Envoy XL 4WD 6-cyl

  • 95,000 miles
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.

- Belleville, MI, USA

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problem #10

Apr 012009

Envoy XL 4WD 6-cyl

  • miles
The contact owns a 2004 GMC Envoy XL. The contact stated that the fuel gauge and speedometer would fluctuate abnormally when driving over 60 mph. The vehicle was taken to the dealer where they were unable determine the failure and the vehicle was not repaired. Updated 06/17/11 updated 06/27/11

- Salinas, CA, USA

problem #9

Apr 052010

Envoy XL

  • 84,000 miles


The contact owns a 2004 GMC Envoy XL. The contact was driving approximately 30 mph as the fuel gage displayed an incorrect reading. The failure recurred at any time. The contact had taken the vehicle to the dealer where they replaced the fuel tank yet the failure continued to recur. A complaint was filed with the manufacturer regarding the fuel tank but no assistance was provided. The failure mileage was 84,000.

- Venetia, PA, USA

problem #8

May 012004

Envoy XL 4WD 6-cyl

  • miles
My gas gauge says I have gas when I keep running out. I have taken to dealership and they replaced gauge. Still does not work.

- Blythewood, SC, USA

problem #7

Apr 052011

Envoy XL 8-cyl

  • 100,000 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. He would not advocate nor deny a faulty part by GMC. We just want our vehicle fixed. My family and I cannot afford to pay $1300. For this repair. This car has so many problems that we cannot keep up with them financially. Currently the air conditioner does not blow, it has worked in several years. The passenger window chooses when it wants to roll down, the cd player just stopped playing after the two years. Often when I put gas inside the car I have to roll the windows down because the fumes are so strong in the backseat where my children sit. We have to put gas inside the car every two days. This car is dangerous to me and my family. I read on the NHTSA website a investigation was conducted and was closed due to GMC willingness to assist the consumer. I mentioned this to the GMC representative and her supervisor that I was aware a investigation was conducted. They indicated they are not aware of a investigation and to their knowledge I am the first GMC consumer to report such a problem. On behalf of my family I am requesting your assistance in this matter. I cringe everytime I have to drive my children in this car. We cannot afford the repair and we cannot afford another vehicle. Please help us in this matter. [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Tulsa , OK, USA

problem #6

Aug 252004

Envoy XL

  • 126,224 miles
2004 Envoy XL VIN [xxx] started as fuel smell, now leaking in the area where fuel pump attach's to tank milage 126224. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Duxbury, MA, USA

problem #5

Jul 292010

Envoy XL

  • 118,000 miles


2004 GMC Envoy xuv dies when in drive and stopped for stop light, stop sign, etc. When the gas is applied, the car dies and I tie up traffic while having to shift to park, restart the engine, and then shift to drive and proceed through the intersection. It never dies while driving, only at a stop. I have had this car to the dealer numerous times and, because there is no "code", they don't know what to do to fix it. The car also has a gas tank that is cracked at the neck and causes the check engine light to be on all the time. The dealership assures me that this is not a safety concern nor does the gas tank crack have anything to do with the engine dying. There is no gas leak but air does get into the tank causing the light to stay on. The throttle body has been cleaned and the entire emission system has also been checked and no one can figure out what the problem is. Dealership also says that the gas tank problem is quite common but that there is no recall..................why not"????" the main computer module was replaced and this has been happening since then.

- Lenexa, KS, USA

problem #4

Jun 062010

Envoy XL 6-cyl

  • 112,000 miles
2004 Envoy GMC XL having the PO442 code come up with signs of gas leaking, smells like gas and evap system seems to not be working. The GMC diagnostic comes up with evap small leak detected. Very similar to the problems on the 2002-2003 Envoy XL.

- Wahiawa, HI, USA

problem #3

Dec 232009

Envoy XL

  • 108,000 miles
Fuel gauge is not working, it even pointed completely South at one time. Looking on the web it seems to be a common problem in Envoy.

- E. Dummerston, VT, USA

problem #2

Jan 232009

Envoy XL

  • 0 miles
2004 Envoy with approx.47,000.had to replace fuel tank due to fracture around filler neck and replace oxygen sensor.was informed extended warranty on fuel tank modular reservoir assembly which contains the fuel pump did not include filler neck I had to pay 1'551.16 dollars for repair.

- Union, NJ, USA

problem #1

Jun 112007

Envoy XL 6-cyl

  • Automatic transmission
  • 57,000 miles
The contact owns a 2004 GMC Envoy XL. The current mileage was 61,000. The check engine warning indicator light illuminated. The vehicle was taken to the dealer who stated that the fuel tank was cracking and had to be replaced. The failure mileage was 57,000.

- Cedar Hill, TX, USA

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