2004 GMC Envoy Xl

The subject vehicles are model year (MY) 2002-2009 Chevrolet Trailblazer, GMC Envoy, 2004-2007 Buick Rainier, 2003-2008 Isuzu Ascender, 2005-2009 Saab 9-7X, 2002-2004 Oldsmobile Bravada, 2003-2006 Chevrolet SSR, 2005-2009 Buick Lacrosse, and 2006-2008 Pontiac Grand Prix. This scope includes the Trailblazer/Envoy variants: 2002-2006 Envoy XL/Trailblazer EXT and 2004-2005 Envoy XUV. The original scope of this investigation was expanded to include all vehicles equipped with the subject Headlight Driver Module (HDM). The focus of the investigation was to determine whether actions performed by General Motors adequately addressed any unreasonable risk to motor vehicle safety in the subject vehicles concerning the headlights and the HDM that controls them.Under normal electrical load and environmental conditions, the HDM can overheat inside the Underhood Electrical Center (UEC). This can cause the module to fail and result in a simultaneous loss of both low beam headlights and both daytime running lights (DRLs), often with no warning or prior detectability to the driver. This failure can be intermittent or permanent. No other exterior lights are affected. High beams, turn signals, brake lights, and reverse lights are still operational.General Motors addressed this issue with 2 recalls (14V755 & 15V519) and a special coverage program (N172091910). In view of the recalls and special coverage program implemented by GM and the vehicle high beams continuing to operate, ODI has tentatively concluded that the actions taken by GM mitigate any unreasonable risk to safety posed by HDM failure in the subject vehicles.Accordingly, the investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take additional action if warranted by new circumstances.The ODI reports cited above are available for review online at NHTSA.gov under the identification numbers in the attached document.

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 VEHICLES WHILE DRIVING.UPON FURTHER EXAMINATION OF THEIR VEHICLES, THEY DISCOVERED THAT FUEL VAPORS WERE COMING OUT OF THE TOP OF THE FUEL TANK. THIS CONDITION IS CAUSED BY CORROSION OF THE RETURN AND SENDER LINES OF THE FUEL PUMP MODULE.WATER AND ROAD SALT COLLECT ON TOP OF THE FUEL PUMP LEADING TO SMALL PINHOLES APPEARING ON THE FUEL LINES.FUEL MAY LEAK AND COLLECT ON TOP OF THE MODULE AND/OR SPILL ONTO THE GROUND.THE DATA EVALUATED UNDER THIS INVESTIGATION REFLECT A RELATIVELY LOW FREQUENCY OF OCCURRENCE THAT LARGELY ARISES IN SALT BELT STATES.GM HAS EXTENDED THE WARRANTY ON THE SUBJECT COMPONENT TO TEN YEARS OR 120,000 MILES.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME; ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION SELECT DOCUMENT SEARCH.

BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.

GM STATES THAT SOME BRAKE/TAIL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO MALFUNCTIONING BRAKE/TAIL LAMP SOCKETS.ON MARCH 2, 2004, GM INITIATED A 6-YEAR/72,000 MILE SPECIAL POLICY FOR 989,487 SUBJECT VEHICLES TO INSPECT AND REPLACE THE REAR BRAKE/TAIL LAMP BULB SOCKET ASSEMBLIES.ON APRIL 4, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-032) BASED ON CONSUMER COMPLAINTS ALLEGING BRAKE LIGHTS NOT OPERATING WHEN THE BRAKE PEDAL IS DEPRESSED.ON AUGUST 3, 2004 ODI UPGRADED PE04-032 TO AN ENGINEERING ANALYSIS (EA04-021).BY LETTER DATED OCTOBER 27, 2004 GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA # 04V527) COVERING SUBJECT VEHICLES THAT WERE NOT ALREADY REPAIRED UNDER GM'S SPECIAL POLICY.MY 2004 SUBJECT VEHICLES BUILT AFTER AUGUST 8, 2003 CONTAIN IMPROVED BRAKE LAMP ASSEMBLIES AND ARE NOT INCLUDED IN THE RECALL.GM DEALERS WILL INSTALL THE IMPROVED BRAKE LAMP ASSEMBLY ON SUBJECT VEHICLES BUILT ON AUGUST 8, 2003 AND EARLIER.THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

The contact owns a 2004 GMC Envoy XL. The contact stated while driving approximately 45 MPH, the accelerator pedal was depressed, and the vehicle stalled. Additionally, the vehicle failed to restart, with several unknown warning lights illuminated. The vehicle was towed to the residence. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and suggested that the vehicle be inspected by a local dealer. The failure mileage was unknown.

NHTSA ID

11517086

Incident

Apr 14, 2023

I WAS DRIVING BACK HOME, PULLED IN MY DRIVEWAY, PUT THE VEHICLE IN PARK AND WHEN I RELEASED THE BRAKE PEDAL THE VEHICLE JUMPED AND TOOK OFF IN REVERSE. I MISSED HITTING MY WIFE BY INCHES. I STOPPED AND RESTARTED THE VEHICLE. IT WOULD NOT START. I TRIED TO PUSH THE BUTTON ON THE SHIFTER.I INTERNET SEARCHED IT WAS SAID TO BE THE LOCKOUT DEVISE. I INSPECTED THE TRANS AND FOUND THE CABLE THAT COME FROM THE SHIFTER TO THE TRANS WAS OFF AND TRANS BRACKET WAS WORN FROM USE. IF IT HAPPENED IN A PARKING LOT I COULD HAVE HIT SOMEONE OR THE VEHICLE BEHIND ME. I CONTACTED GMC NO KNOWLEDGE OF THE SAFETY PROBLEM I HAVE DESCRIBED. MY CASE FILE IS[XXX]. I TALK WITH AMY AND JUNAID AT EXT 42846. THEY TOLD ME I HAD TAKE IT TO THE DEALER FOR INSPECTION TO DETERMINE IF IT IS A DEFECT OR WEAR AND THAT THE DEALER WOULD TAKE 1 HR TO INSPECT THE VEHICLE WHICH I WOULD HAVE TO PAY FOR. I THEN CALLED 2 DEALERS LOVE CHEVROLET INVERNESS FL 34453 AND EAGLE BUICK, PONTIAC & GMC TRUCK HOMOSASSA FL. I WAS TOLD BOTH SERVICE REPS THAT THIS HAPPEN ALL THE TIME AND THEY WOULD CONFIRM THAT IT WAS DUE TO WEAR AND NOT A DEFECT. BUT IN YOU MANUAL THERE IS NO PROVISIONS TO INSPECT THE SHIFTING CABLE WITH IS A SAFETY PROBLEM WHICH GM AND THE DEALER ARE AWARE OF BUT IGNORE AND TELL YOU HAVE TO BUY A NEW CABLE FOR $75.00 INSTEAD OF SUPPLYING THE BUSHING THAT HAS BEEN WORN OUT THAT IS PRESS FIT INTO THE CABLE THE ONLY DEFECT ON THE CABLE IS THE BUSHING WHICH COST AT MOST $3.00 AND A VERY EASY FIT. I HAVE A BUICK RAINER WITH THE SAME DEFECT VIN[XXX] THE WAY IT WAS REPAIRED WAS THE SHIFT LEVER ON THE TRANS PIN WAS REMOVER AND A BOLT AND NUT WERE PUT IN PLACE OF THE OEM PIN ON SHIFTER AND IT WAS BOLTED TO THE SHIFTER END OF THE CABLE NO OEM REPAIR THIS VEHICLE WAS SOLD TO ME BY GM EAGLE BUICK. I OWN 2 GM VEHICLES WITH THE SAME SAFETY PROBLEM. PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).*JS

NHTSA ID

11242594

Incident

Jun 27, 2013

DRIVING AT A LOW SPEED DOWN HILL ON A CITY STREET, WITH THE CAR IN THE DRIVE POSITION, THE CAR STALLED. THIS HAPPENED AGAIN DRIVING ON A FLAT SERVICE OF A PARKING LOT OF A SHOPPING CENTER. AGAIN, WITH THE CAR IN THE DRIVE POSITION GOING AT A LOW SPEED THE CAR STALLED.

NHTSA ID

11163923

Incident

Dec 18, 2018

Mileage

145,000 mi

FOUR VEHICLE ACCIDENT, #THREE VEHICLE IN LINE FROM THE FRONT. TRAVELING AT POSTED SPEED LIMIT OF 60MPH. SUDDEN HARD BRAKING, HIT IN THE FRONT & REAR OF THE VEHICLE, VEHICLE WAS CONSIDERED A TOTAL RIGHT OFF. NO AIR BAG DEPLOYMENT ON DRIVER OR PASSENGER IN FRONT SEAT! RUSH HOUR TRAFFIC ON FOUR LANE ST. HWY., DFW, TX. MARCH OF 2014.

NHTSA ID

11133420

Incident

Mar 12, 2014

Mileage

85,000 mi

TL* THE CONTACT OWNS A 2004 GMC ENVOY XL. WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE INADVERTENTLY DECELERATED. THE CONTACT STOPPED AT A FUEL STATION AND PROCEEDED TO CHECK ALL THE FLUID LEVELS. THE CONTACT CONTINUED TO DRIVE AND THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE CONTACT COULD ONLY OPERATE THE VEHICLE IN FIRST AND SECOND GEARS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DETERMINED THAT THE TRANSMISSION FAILED AND NEEDED REPLACEMENT. THE VEHICLE WAS NOT REPAIRED. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND COMPLAINT NUMBER: 84441281449 WAS FILED. THE APPROXIMATE FAILURE MILEAGE WAS 140,395. *TT CONSUMER STATED THE VEHICLE HAS BEEN REPAIRED WITH A REMANUFACTURED TRANSMISSION IT IS A KNOW FACT IN THE AUTOMOTIVE INDUSTRY THAT GM IS AWARE OF THE FAULTY CONSTRUCTION OF TRUCK TRANS MISSIONS. MY TRANSMISSION WAS SERVICED ABOVE AND BEYOND THE MANUFACTURED RECOMMENDATION. THE ATTACHED DOCUMENT FROM JASPER TRANSMISSION DEMONSTRATED ALL THE AREAS THAT THEY NEED TO ADDRESS BECAUSE OF ALL THE SAFETY FAILURES IN THE ORIGINAL MANUFACTURING. THE FAILURES WITHOUT NOTICE CAUSING A MAJOR SAFETY ISSUE. ENGINE-TRANSMISSION-EXCHANGE ADDRESSED THE SAME ISSUES WHEN REMANUFACTURING. SEE ATTACHED DOCUMENTS FROM JASPER TRANSMISSION AND THE PACKING SLIP OF THE PURCHASED TRANSMISSION ADVANCE AUTO INSTALLED AT THE AUTO CENTER (SEE VIN NUMBER). UPDATED 10/22/18*JB

NHTSA ID

11118061

Incident

Jul 15, 2018

Mileage

140,395 mi

TL* THE CONTACT OWNS A 2005 (NA) GMC ENVOY XL. THE CONTACT STATED THAT THE LOW BEAM HEADLIGHTS FAILED TO ILLUMINATE. THE CONTACT WAS ABLE TO DRIVE HOME WITH THE HIGH BEAMS ACTIVATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT BODY SHOP AND THE MECHANIC STATED THAT THE LOW BEAM LIGHTS NEEDED TO BE REPLACED; HOWEVER, THE CONTACT WAS NOT ADVISED AS TO WHAT CAUSED THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER STATED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07E014000 (EXTERIOR LIGHTING). THE FAILURE MILEAGE WAS 129,000.

NHTSA ID

10992825

Incident

May 29, 2017

Mileage

129,000 mi

TL* THE CONTACT OWNS A 2004 GMC ENVOY XL. WHILE DRIVING VARIOUS SPEEDS, THE TURN SIGNAL INDICATORS BECAME INOPERABLE WITHOUT WARNING. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 184,000.

NHTSA ID

10969316

Incident

Mar 15, 2017

Mileage

184,000 mi

MY 2004 GMC ENVOY XL SLT IS LEAKING GAS AT THE GAS TANK AND THE FILLER HOSE GAS JUST RUNS DOWN THE TANK TO THE GROUND ITS A FIRE RISK

NHTSA ID

10957445

Incident

Feb 27, 2017

Mileage

105,000 mi

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.