Research · Sport Utility Vehicle - 2WD

2004 GMC Envoy XLRecalls, problems, MPG & safety

NHTSA lists 1 safety recall and 718 owner complaints for the 2004 GMC Envoy XL. Most complaints involve electrical system (329) and fuel system, gasoline (63). The EPA rates it 15–16 mpg combined.

Combined MPG
15–16mpg
EPA · 4 versions
NHTSA overall
—
Not rated by NCAP
Safety recalls
1campaigns
Latest Nov 2004
Owner complaints
718
Top: electrical system
Fuel cost / yr
$3,900est.
EPA estimate, best version
01 —Recalls

Safety recalls

1 NHTSA campaign · applies to some vehicles, check your VIN

Exterior lighting: brake lights

Free remedy

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.

Exterior lightingReported Nov 1, 2004NHTSA 04V527000
Data from NHTSA Recalls API · synced Nov 7, 2026 · All recall detailsNHTSA vehicle page
02 —Complaints

Owner complaints by component

718 complaints filed with NHTSA · Jan 2004 – Dec 2025
  1. Electrical system329
  2. Fuel system, gasoline63
  3. Exterior lighting60
  4. Fuel/propulsion system58
  5. Air bags47
  6. Engine and engine cooling41
  7. Power train40
  8. Visibility36
  9. Vehicle speed control33

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

By model year

Complaints for each Envoy XL model year we’ve synced.

View as table
Model yearNHTSA complaints
2002570
2003642
2004718
2005624
2006603
Crashes reported
35
Fires reported
18
Injuries reported
44
Deaths reported
1
Data from NHTSA Complaints API · synced Nov 7, 2026 · Full problem breakdownNHTSA vehicle page
03 —Common problems

What owners report most

Verbatim excerpts from NHTSA complaints, by component

Electrical system

329 reports1 crash8 fires
“The contact owns a 2004 GMC Envoy. The contact stated that while the vehicle was parked and unoccupied, the contact noticed that the front passenger's door was on fire. The contact stated that he arrived home just in time and noticed the fire. The contact stated that, because it was raining, the contact's wife had powered the window up; however, the contact noticed that the window was down when the fire occurred. In addition, the contact stated that the fire was blazing, and after the fire was extinguished, the smoke was still visible. The contact extinguished the fire. The contact disconnected the battery. In addition, the contact stated that it could have been a huge fire because the fuel tank had just been refilled prior to the failure. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 133,295.”
Owner complaint to NHTSAFiled Dec 17, 2025Electrical systemFire reportedODI 11705548

Fuel system, gasoline

63 reports
“VEHICLE HAS HAD STRONG ODOR OR RAW FUEL COMING FROM DRIVING SIDE WHEEL WELL. HAD MECHANIC CHECK THIS OUT AND I WAS TOLD THIS HAS A FUEL LEAK NEAR THE FUEL FILTER / FILLER NECK AND POSSIBLE GAS TANK ISSUE WHICH IS CLOSE TO THE EXHAUST PIPE. THIS IS A KNOWN ISSUE FROM GM OWNERS BUT RECALL HAS NOT BEEN ADVISED. INFORMED GM OF ISSUE ON 10/26 BUT THEY WILL NOT FIX. THIS WILL COST UPWARDS OF $1100-$1600 TO FIX. *TR”
Owner complaint to NHTSAFiled Oct 27, 2016Fuel system, gasolineODI 10919399

Exterior lighting

60 reports3 crashes
“Headlight's,taillight's,turn signals stop working whenever they want.It's pretty scary to lose your headlight's when your driving at night.There's nothing i can do about it,except to sit wherever it happend and wait for them to come back on.My wife was following me one day and told me my brakelight's and turn signal stopped working and started to work again,she said this happened a couple time's at the same red light.There a couple of thing's (electrical)inside the vehicle that don't work anymore but i really dont care about them.To get the odometer to work i have to knock pretty hard on the plastic cover that cover's the instrument cluster,sometimes it stay's on,most of the time it wont stay on.The DIC (driver control center) doesn't work anymore.I cant even get to it.The speakers on the left side of the vehicle dont work anymore.I thought i would tell you about the inside also because it could be part of the problem.All of this happened when i was driving home from my daughter's two night's ago.I bought this vehicle about three or four's year's ago,and i had no problem's with it untill the other night.The person i bought it from is a good friend of mine.He…”
Owner complaint to NHTSAFiled Aug 9, 2022Electrical system, Exterior lightingODI 11478324
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 7, 2026
04 —Key specs

Engines, transmissions & drive

4 versions rated by the EPA
EPA class
Sport Utility Vehicle - 2WD, Sport Utility Vehicle - 4WD
Engines
5.3L 8-cyl · 4.2L 6-cyl
Transmissions
Automatic 4-spd
Drive
Rear-Wheel Drive · 4-Wheel or All-Wheel Drive
Fuel
Regular Gasoline

Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.

Data from EPA fueleconomy.gov · synced Nov 7, 2026EPA listing
05 —Fuel economy

EPA fuel economy by version

City / highway / combined, annual fuel cost and CO₂
EPA
VersionCityHwyComb.Fuel / yrCO₂ g/mi
Envoy XL 2WD
Auto 4-spd, 8 cyl, 5.3 L · Rear-Wheel Drive
141816$3,900555
Envoy XL 2WD
Auto 4-spd, 6 cyl, 4.2 L · Rear-Wheel Drive
131815$4,150592
Envoy XL 4WD
Auto 4-spd, 6 cyl, 4.2 L · 4-Wheel or All-Wheel Drive
131815$4,150592
Envoy XL 4WD
Auto 4-spd, 8 cyl, 5.3 L · 4-Wheel or All-Wheel Drive
131715$4,150592
  • Envoy XL 2WD
    Auto 4-spd, 8 cyl, 5.3 L
    14 city · 18 hwy · $3,900/yr
    16
    mpg comb.
  • Envoy XL 2WD
    Auto 4-spd, 6 cyl, 4.2 L
    13 city · 18 hwy · $4,150/yr
    15
    mpg comb.
  • Envoy XL 4WD
    Auto 4-spd, 6 cyl, 4.2 L
    13 city · 18 hwy · $4,150/yr
    15
    mpg comb.
  • Envoy XL 4WD
    Auto 4-spd, 8 cyl, 5.3 L
    13 city · 17 hwy · $4,150/yr
    15
    mpg comb.
Data from EPA fueleconomy.gov · synced Nov 7, 2026 · Fuel cost is EPA’s annual estimate (15,000 mi, 55% city)
06 —Safety

NHTSA 5-Star Safety Ratings

1 tested variant
NHTSA has not published 5-Star Safety Ratings for the 2004 GMC Envoy XL as of Nov 7, 2026.
Data from NHTSA NCAP Safety Ratings API · synced Nov 7, 2026Vehicle 1133
07 —Maintenance

Maintenance basics

General guidance, not the OEM schedule. Check your owner’s manual.
General guidance
ItemMilesTimeNote
Engine oil & filter5,000–10,000 mi6–12 monthsFollow the oil-life monitor if fitted
Tire rotation5,000–7,500 miEvery oil changeCheck pressure monthly
Engine air filter15,000–30,000 mi1–2 yearsSooner in dusty areas
Cabin air filter15,000–25,000 mi1–2 years
Brake fluid—2–3 yearsAbsorbs moisture over time
Coolant60,000–100,000 mi5–10 yearsLong-life coolants last longer
Spark plugs60,000–100,000 mi—Iridium/platinum plugs at the long end
12V battery—3–5 yearsHeat shortens battery life
  • Engine oil & filter5,000–10,000 mi
    6–12 months
  • Tire rotation5,000–7,500 mi
    Every oil change
  • Engine air filter15,000–30,000 mi
    1–2 years
  • Cabin air filter15,000–25,000 mi
    1–2 years
  • Brake fluid—
    2–3 years
  • Coolant60,000–100,000 mi
    5–10 years
  • Spark plugs60,000–100,000 mi
    —
  • 12V battery—
    3–5 years
Typical intervals for modern cars. Severe service (towing, short trips, extreme heat or cold) shortens them.
09 —FAQ

2004 Envoy XL questions

How many recalls does the 2004 GMC Envoy XL have?

1 safety recall as of Nov 7, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.

What are the most common 2004 GMC Envoy XL problems?

Owners filed 718 complaints with NHTSA. The most-cited components are electrical system (329), fuel system, gasoline (63), exterior lighting (60). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.

What MPG does the 2004 GMC Envoy XL get?

The EPA rates the 2004 GMC Envoy XL at 15–16 mpg combined, depending on engine and drivetrain (4 versions rated).

Data from NHTSA & EPA · synced Nov 7, 2026