2003 GMC Envoy

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.

ODI HAS RECEIVED REPORTS THAT THE FUEL PUMP MODULE LEAKS FUEL AND OR VAPOR UNDERNEATH THE VEHICLE.GM STATES, THE FAILURE MECHANISM IS CORROSION OF THE FUEL PUMP MODULE FLANGE WHICH MAY LEAD TO A FUEL LEAK.CORROSION OF THE FUEL PUMP MODULE FLANGE IS THE RESULT OF THE VEHICLE OPERATING IN A CORROSIVE ENVIRONMENT.ODI HAS UPGRADED THIS PE TO ENGINEERING ANALYSIS (EA07-009) TO FURTHER ASSESS THIS ISSUE.

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.

My windshield wipers come on when you start the car, or when you just click the switch to put windows up, but the wiper switch is off. The wipers stay operating from 5 to 10 minutes before they shut off, and I am concerned the windshield and/or wipers may become damaged. This issue has just started to occur within the last week. There have been no warning messages of any type displayed.

NHTSA ID

11753078

Incident

Jul 20, 2026

The contact owns a 2003 GMC Envoy. The contact stated that while in drive(D), the vehicle shut off and then restarted. The message “Service Engine Soon” was displayed. The vehicle was taken to the local dealer, where it was diagnosed and determined that the instrument cluster needed to be replaced. The vehicle was repaired, but the failure reoccurred. The vehicle was taken back to the dealer who installed the original instrument cluster, but the failure persisted. The manufacturer was not notified of the failure. The approximate failure mileage was 98,000.

NHTSA ID

11723763

Incident

Feb 27, 2026

Mileage

98,000 mi

The contact owns a 2003 GMC Envoy. The contact stated that while the vehicle was parked on several occasions, there was condensation under the front of the vehicle. The vehicle was taken to a dealer on several occasions, where it was determined that the differential needed to be repaired due to a leak coming from the axle. On several occasions, it was determined that the rear pinion seal needed to be replaced. The contact stated that the rear pinion seal was replaced on several occasions. The manufacturer was notified of the failure. The failure mileage was approximately 66,411.

NHTSA ID

11714974

Incident

Mar 13, 2008

Mileage

66,411 mi

Fuel indicator bounces from Empty to full in the matter of seconds while going down the road. Also, issues with mileage range reported as the fuel indicator is fluctuating.

NHTSA ID

11671427

Incident

May 1, 2025

The car's gas gauge and fuel range indicator are problematic. The fuel gauge quickly drops from a higher reading, like 3/4 full, to empty. After this, the gauge and the fuel range both fluctuate while driving, making it impossible to determine the fuel level.

NHTSA ID

11671416

Incident

May 1, 2025

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.

NHTSA ID

11615468

Incident

Aug 9, 2024

ISSUE: Hazard Warning/Turn Signal Flasher Module Failure. DESCRIPTION: Right front and rear turn signal and right front and rear hazard warning not working outside or inside vehicle. Replaced burned out right front turn signal/hazard. Replaced right rear turn signal/hazard due to corrosion on base of bulb. Looked at fixtures when replacing and all appeared good but right turn signals and right hazard warnings still not operational outside or inside vehicle. AVAILABLE FOR INSPECTION: Yes, upon request. RISK/DANGER: Cannot use right blinker or hazard warning flashers to notify approaching or oncoming vehicles of right turn or hazard which could cause other vehicles to crash into stopped or slowing vehichle. CONFIRMED: No. INSPECTED: Not by anyone other than myself [XXX] , daughter of [XXX] owner). ANY KIND OF WARNING & WHEN IT BEGAN: No warning or symptoms really, just didn't work one minute, then worked momentarily and then didn't work and has not worked since. Was taking vehicle in for required State inspection on when the above described issue occurred, so went back home so it would not fail inspection. Occurred during daytime hours. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11590869

Incident

May 23, 2024

The contact owns a 2003 GMC Envoy. The contact stated that the headlights ceased to operate as needed. Upon taking the vehicle to a local Pep Boys, it was diagnosed that the electrical wiring harness was burned and needed to be replaced. Additionally, the bulbs needed to be replaced. The contact stated that the vehicle was repaired; however, the failure recurred. The vehicle was taken back the local Pep Boys, who replaced the electrical wiring harness and the bulbs a second time; however, the failure persisted. The dealer and the manufacturer were not notified of the failure. The vehicle was not repaired. The failure mileage was unknown.

NHTSA ID

11515670

Incident

Apr 5, 2012

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 vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester  and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.

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.