Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 GMC Envoy owners, lightly cleaned up (personal details are redacted by NHTSA).
Vehicle was being driven on a two way highway at approximately 55 MPH. Vehicle lost engine power while driving and the gas pedal lost resistance and went to the floor. Vehicle was steered over to the side of the road. While the vehicle was steered over to the side of the road, check engine and other dash lights started flashing chaotically. White smoke started coming from under the hood. Within a short time, white smoke turned into black smoke and then flames started to appears. The fire under the hood eventually continued to grow until it completely burned the engine compartment most of the first two rows of the interior before the firemen arrived and were able to put out the fire.
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.
The transmission started to slip, noticed it starting to have issues getting up to proper speed without slipping and trying to stall, and was told by previous owner whom I'm purchasing it from that there is a possible issue with the transfer case as well, as it engages it's 4 wheel drive without me touching it, tried to service the transmission and put fresh fluid and a new filter in to see if it would help and now it can only go as fast as 40 to 55 before it starts to slip pretty bad. I have a baby on the way due in the next couple weeks and with it slipping and dropping speed it can cause me to end up getting hit and I don't want to put mine, my child, or any of my other passengers in danger.
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. Won't pass smog can't register vehicle, but my only means of transportation. 2004 GMC Envoy xuv slt 4dr 2wd
Tl* the contact owns a 2004 GMC Envoy. While the vehicle was idling, there was a strong fuel odor. The contact noticed the fuel was leaking out of the fuel tank. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel tank ruptured and the entire fuel tank needed replacement along with the fuel pump and the fuel lines. The vehicle was not repaired due to the parts not being available. The manufacturer was notified of the failure. The approximate failure mileage was 168,000.
Recently, when the A/C or heater is turned on, the smell of fuel comes thru the air vents. It is a strong odor which last for a few minutes to sometimes longer. I have to put the windows down in order to not get dizzy or get a headache. The vehicle be in motion or still for this to happen. Mileage is around 95,000. I've heard it's a cracked fuel line or fuel tank and read many complaints about the same; therefore, why no recall?
Tl* the contact owns a 2004 GMC Envoy. While the vehicle was parked, an abnormal fuel odor was present on the inside and outside of the vehicle. The contact stated that there was evidence of a fuel leak coming from the fuel filler neck. The vehicle was not diagnosed or repaired. The manufacturer was notified. The approximate failure mileage was 109,000. The VIN was not available. ..updated 05/05/17
Tl* the contact owns a 2004 GMC Envoy. While the vehicle was parked, the contact noticed fuel leaking underneath. The vehicle was towed to an independent mechanic where it was diagnosed that there was a hole in the filler neck that needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 157,000. The VIN was not available.
Tl* the contact owns a 2004 GMC Envoy. In March of 2015, the neck of the fuel tank fractured. The contact had the vehicle diagnosed by an independent mechanic who diagnosed that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was notified. The failure mileage was 133,000. Updated 11/09/15 updated 12/09/15.
Tl* the contact owns a 2004 GMC Envoy. The contact stated that the fuel tank was leaking fuel. The vehicle was taken to an independent mechanic who diagnosed that an unknown part needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure, but did not offer any assistance. The failure mileage was 190,000.
NHTSA investigations
Fuel pump module leaks gasoline
During the course of this ea investigation, odi observed that the majority of the complaints (88%) and warranty claims (94%) were reported for vehicles that are registered for use in the salt belt region of the us.this area includes 20 states in the northeast, mid atlantic and the midwest regions and the district of columbia.consumers in the salt belt region reported to odi that they could smell fuel vapors in their…
Fuel System complaints in other Envoy years
Frequently asked questions
How common are fuel system problems on the 2004 GMC Envoy?
NHTSA has 67 complaints about the fuel & propulsion system of the 2004 GMC Envoy, 18% of the model year's 367 complaints. The component named most often is storage › fuel gauge system (3 mentions).
Is there a recall for 2004 GMC Envoy fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 GMC Envoy, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 GMC Envoy fuel system problems start?
Half of the complaints with a recorded mileage happened before about 107,000 miles, and 5% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 fires and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.