Problems · by component

2003 GMC Envoy structure problems

56 owner complaints to NHTSA about the 2003 GMC Envoy cite structure, 9% of all 642 complaints for this model year.

Complaints
56
9% of all complaints
Crashes
2
Reported by owners
Fires
0
Reported by owners
Injuries
14
Reported by owners
01 —Owner reports

What owners say about the structure

Verbatim from NHTSA complaints, newest first
“I bought a 2003 GMC Envoy 3/23/24. The main frame and sub-frame have extensive rot, and is unsafe to drive. It is available to inspect. They disguised frame damage and sold me an unsafe vehicle. I brought the car in to have the ac repaired in August 2024 and when they put it up on the lift that's when they saw the damage. This was Rogers Automotive in Westport MA. They told me at that time that it is unsafe to drive. It has not been inspected by any other parties at this time. We had no idea it was damaged, Rogers said it was sprayed to try to hide the damage.”
Owner complaint to NHTSAFiled Sep 19, 2024StructureODI 11615468
“MY WIFE WAS SITTING IN THE BACKSEAT AND THE BACK DOOR FLEW OPEN ON THE HIGHWAY. I HAVE ALSO NOTICED THE OTHER BACK DOOR IS NOT CLICKING SHUT AND THIS IS A VERY DANGEROUS SITUATION. *TR”
Owner complaint to NHTSAFiled May 11, 2020Air bags, StructureODI 11324152
“DRIVER DOOR WILL LOCK AND UNLOCK ELECTRONICALLY BUT IF YOU TRY TO UNLOCK DOOR MANUALLY IT DOES NOT UNLOCK. IF CAR CRASHES PERSON COULD GET TRAPPED IF CAR IS ON FIRE COULD CAUSE A DEATH IF NO POWER TO ELECTRONIC LOCKS”
Owner complaint to NHTSAFiled Apr 13, 2019StructureODI 11196075
“TL* THE CONTACT OWNS A 2003 GMC ENVOY. WHILE DRIVING APPROXIMATELY 25 MPH, THE FRONT END OF THE VEHICLE COLLAPSED. THE VEHICLE WAS TOWED TO A LOCAL DEALER (ROBERTSON'S GMC TRUCK, 2680 CRANBERRY HWY, WAREHAM, MA 02571) WHERE IT WAS DIAGNOSED THAT THE FRAME ASSEMBLY NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND OFFERED NO FURTHER ASSISTANCE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000. THE VIN WAS NOT AVAILABLE. *TT *TR”
Owner complaint to NHTSAFiled Feb 20, 2018StructureODI 11073784
“WE PURCHASED OUR 2003 GMC ENVOY XL SLE 8 CYLINDER BRAND NEW AT ALDEN BUICK IN FAIRHAVEN, MASS IN JULY 2003; FOR THE PAST 3 YEARS WE HAD IT SERVICED AT ROBERTSSON'S GMC 2680 CRANBERRY HIGHWAY, WAREHAM, MASS.02571,508-291-0044. WE HAD IT RECONDITIONED AT THIS DEALERSHIP LAST YEAR, SPENDING $4000.00; WE HAD IT INSPECTED AT THIS DEALERSHIP WITH THE MASSACHUSETTS VEHICLE CHECK; IT PASSED THE FRONT END CHECK AND FRAME CHECK ON 8/4/17. I WAS DRIVING THE VEHICLE IN LATE DECEMBER, AND HIT SEVERAL DEEP POTHOLES CAUSED BY AN ICE STORM; SHORTLY THEREAFTER I LOST STEERING CONTROL OF THE VEHICLE. I HAD IT TOWED TO ALDEN BUICK/GMC IN FAIRHAVEN, MASS. TO BE TOLD THAT THE ENTIRE FRAME HAD COLLAPSED DUE TO EXTENSIVE CORROSION AND RUST. I HAD IT TOWED TO ROBERTSON'S GMC IN WAREHAM AND FILED A CLAIM WITH COMMERCE INS. CO. TO HOPEFULLY COVER THE DAMAGE TO THE FRAME; COMMERCE DENIED THE CLAIM STATING"THE FRAME ASSEMBLY WAS SEVERELY ROTTED AND THIS EXTENSIVE ROT ALLOWED THE RIGHT FRONT CONTROL ARM TO BREAK AWAYFROM THE MOUNTING POINT ON THE FRAME RAIL. GMC ISSUED A TECHNICAL SERVICE BULLETIN STATING THAT SOME ENVOY MODELS SUFFERED FROM EXTENSIVE FRAME CORROSION. WHY DID ROBERTSON'S…”
Owner complaint to NHTSAFiled Feb 8, 2018Suspension, StructureODI 11071689
“IT STARTED WITH ENGINE MISFIRING CAUSING ENGINE TO JOLT WHICH DAMAGED #4 COIL PACK SEAL TO FAILED ALLOWING WATER INTRUSION. IN 2008, THE GMC MECHANIC REPLACED ALL SIX COILS SEALS BUT IN 2013-PRESENT P0440 ENGINE CODE IS A LEAK IN THE EVAPORATIVE EMISSION (EVAP). LOOSE FUEL TANK FILLER CAP IS THE MOST COMMON CAUSE THAT TRIGGERS THE P0440 CODE. I FAILED A FEW SMOG CHECK SPENDING HUNDREDS OF THOUSANDS OF DOLLARS YET MY PROBLEM STILL EXISTENCE. I'VE CONTACTED THE BUREAU OF AUTOMOTIVE REPAIR BECAUSE PURRFECT AUTO IN FULLERTON,CA LIED ABOUT FIXING MY CAR. THE BAR MADE PURRFECT AUTO REPLACE THE GAS TANK AND GAS CAP YET THE ENGINE LIGHT IS STILL ON DISPLAYING CODE P0440. ITS BEEN 14 YEARS AND I'M STILL DEALING WITH THIS PROBLEM.”
Owner complaint to NHTSAFiled May 6, 2017Structure, Engine, Fuel/propulsion systemODI 10983794

Showing 6 of 56 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 28, 2026NHTSA vehicle page

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