The 2004 GMC Envoy has no open NHTSA recalls. Owners report 6 recurring issue clusters, led by “Fuel tank and filler neck leak with fuel odor.” GMC trucks and SUVs use the GM Oil Life System (OLS) — the same algorithm as Chevrolet. Because GMC's lineup is exclusively trucks and SUVs, severe-service intervals apply to most owners (towing, hauling, off-roading). The schedule below surfaces the items most relevant to GMC's truck-focused buyer.
No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.
What drivers and federal regulators have officially reported about the 2004 GMC Envoy.
FUEL/PROPULSION SYSTEM
49 NHTSA complaints · 2010-08 → 2019-10
“FUEL TANK CHECK VALVE MOUNT SEPARATES FROM TANK CAUSING A LEAK”
“FILLER NECK ON GAS TANK HAS FRACTURED CAUSING GAS VAPORS AND POSSIBLY GAS TO ESCAPE THE TANK”
“THE FUEL TANK NECK WHERE THE FUEL GOES INTO THE VEHICLE THEN DOWN TO THE GAS TANK IS CRACKED WHICH IS CAUSING A GAS LEAK & VAPORS”
ELECTRICAL SYSTEM
40 NHTSA complaints · 2010-06 → 2018-02
“THE INSTRUMENT PANEL CLUSTER ON MY GMC ENVOY 2004 IS DEFECTIVE AS IT IS ON A MULTITUDE OF OTHER GM MODELS BETWEEN 2003 AND 2005”
“FAULTY DASH CLUSTER/SPEEDOMETER. WILL READ 120 MPH WHEN YOU ARE SITTING STILL”
“ONE DAY ALL MY GAUGES MAY WORK I MIGHT SHUT THE SUV OFF AND START IT AGAIN AND NO GAUGES WILL WORK (SPEED,OIL PRESSURE,BATTERY,GAS,ODOMETER,TACH)”
VISIBILITY
12 NHTSA complaints · 2010-12 → 2019-08
“WHILE THE VEHICLE WAS PARKED, THE REAR WINDOW SUDDENLY EXPLODED”
“THE CONTACT STATED THAT THE REAR WINDOW GLASS SHATTERED IN PIECES WHILE THE WINDOW WAS CLOSED”
“THE BACK WINDOW ON MY GMC ENVOY 2004 EXPLODED WHEN MY SON WAS CLOSING IT”
EXTERIOR LIGHTING
17 NHTSA complaints · 2012-10 → 2022-08
“THE HEADLINES TURN OFF BY THEMSELVES WHILE I AM DRIVING AT NIGHT”
“THE CONSUMER STATED HEADLIGHT CONNECTOR MELTED, DUE TO OVERHEATING”
“LOW BEAM HEADLIGHTS TURN ON AND OFF WITHOUT WARNING...EITHER IN MOTION OR STATIONARY”
AIR BAGS
7 NHTSA complaints · 2014-05 → 2020-12
“VEHICLE RAN OFF ROAD, CRASHED INTO PARKED TRUCK, AIR BAG DID NOT DEPLOY”
“THE AIRBAGS DID NOT DEPLOY”
“THE AIR BAGS FAILED TO DEPLOY”
ENGINE
9 NHTSA complaints · 2011-11 → 2023-07
“WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE WOULD STALL WITHOUT WARNING”
“THE CONTACT STATED WHILE DRIVING APPROXIMATELY 30 MPH, THE VEHICLE STALLED WITHOUT WARNING AND THE SERVICE ENGINE LIGHT ILLUMINATED”
“MY GMC ENVOY STALLS OUT WHEN I STOP AT TRAFFIC LIGHTS”
Issues on other model years
Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.
We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.
Critical for safety and preventing major damage
Change oil when OLS reaches 0% or every 12 months. dexos1-approved synthetic required on Sierra 1500 5.3L/6.2L; dexos2 specified on Duramax diesel.
Estimated cost — typical U.S. ranges
Dealer
~$120–$160
Shop
~$85–$115
DIY
~$25–$55
Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.
Rotate tires every 7,500 miles. Sierra and Yukon owners running 4x4 should rotate every 5,000-7,500 miles to even out drivetrain wear.
Estimated cost — typical U.S. ranges
Dealer
~$85
Shop
~$60
DIY
Free
Often free at the shop where you bought the tires — worth asking before paying.
Inspect pads, rotors, and parking brake every 7,500 miles. Towing accelerates pad wear by 30-50%; check more often if towing regularly.
Estimated cost — typical U.S. ranges
Dealer
~$85
Shop
~$60
DIY
Free
Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.
DOT 3 brake fluid: test annually, replace when moisture exceeds 3% or fluid is darker than copper.
Estimated cost — typical U.S. ranges
Dealer
~$180–$200
Shop
~$125–$140
DIY
~$10–$25
DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.
Keeps your vehicle running smoothly and efficiently
Long-life cellulose filter rated 45,000 miles. Trucks driven on unpaved roads or construction sites should inspect at every oil change.
Estimated cost — typical U.S. ranges
Dealer
~$60–$95
Shop
~$45–$70
DIY
~$15–$40
5-minute job on most cars; the airbox lid usually has clips, no tools needed.
Severe service (towing 5,000+ lbs regularly, heavy stop-and-go): every 45,000 miles. Normal: 97,500 miles. Use Dexron-VI for 6L80/6L90, Mobil 1 LV ATF HP for 10L80/10L1000.
Estimated cost — typical U.S. ranges
Dealer
~$330–$500
Shop
~$235–$355
DIY
~$60–$180
Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.
On 4WD models, replace every 45,000 miles. Use GM Auto-Trak II for active 4WD; GM 9986115 for selectable 4WD.
Estimated cost — typical U.S. ranges
Dealer
~$105–$140
Shop
~$75–$100
DIY
~$15–$40
AWD/4WD vehicles only. Easy drain-and-fill on most platforms.
Replace front and rear axle fluid every 50,000 miles, or 25,000 miles if towing. G80 limited-slip rear axles require GM friction-modifier additive.
Estimated cost — typical U.S. ranges
Dealer
~$150–$195
Shop
~$105–$135
DIY
~$20–$50
Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.
Iridium spark plugs on the L83/L84 5.3L and L86/L87 6.2L V8 are rated 100,000 miles. AFM/DFM cylinder deactivation can cause uneven plug wear — check at 75,000 miles.
Estimated cost — typical U.S. ranges
Dealer
~$285–$390
Shop
~$200–$275
DIY
~$25–$100
Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.
Dex-Cool (orange): first change at 150,000 miles or 5 years, then every 50,000. Duramax diesel uses ELC (red) — different chemistry, do not mix.
Estimated cost — typical U.S. ranges
Dealer
~$285–$330
Shop
~$200–$235
DIY
~$25–$60
Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.
Extends the life of your vehicle and improves comfort
Replace cabin air filter every 22,500 miles. Sierra HD and Yukon XL owners in dusty work environments should replace at 15,000 miles.
Estimated cost — typical U.S. ranges
Dealer
~$60–$95
Shop
~$45–$70
DIY
~$15–$40
Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.
Occupant deaths in fatal crashes (FARS)
379 crashes 1990–2024
How the 379 occupant deaths break down
258
driver deaths
121
passenger deaths
379
occupant deaths
Crash years covered: 1990–2024 This model year first appears in 2004 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.
FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number
FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.
Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.
Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.
IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.
Owner-reported problem signals
Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.
25
complaints mentioning a crash
11
complaints mentioning a fire
Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.
How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.
This maintenance schedule for the 2004 GMC Envoy reflects GMC's published service intervals and the Oil Life System system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.