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Common GMC Envoy Failures: Breakdowns, Tips & Problems!

The GMC Envoy is a fairly reliable midsize SUV. Unfortunately, after a seven-year production run, this SUV was discontinued in 2009. If you’re interested in buying a car like this, consider taking the time to learn about common GMC Envoy faults .

If you decide to buy a used 2009 GMC Envoy, you should know that the depreciation rate of this SUV in 5 years is 7%. That means that from its current price it is the equivalent of 7,300 US dollars, and its value is expected to drop to $6,800 in five years.

How good are the GMC Envoys?

Since the GMC Envoy was discontinued in 2009, many vehicle reliability rating websites do not have enough information about the reliability ratings of this SUV.

For example, at the time of writing, there is not enough data to give the GMC Envoy a reliability rating, as well as estimates of the average severity of repairs and frequency of repairs. But if you know that the annual maintenance cost for the GMC Envoy is approximately $497, which is less than the annual repair cost of $573 for all midsize SUVs

Reliability ratings are only available for the 2006-2009 GMC Envoy. The model year that received the highest overall customer ratings and reliability ratings is the 2006 Envoy, scoring 85/100 in both categories.

The model year with the lowest reliability rating is the 2007 Envoy, with a score of 83/100. The average customer and reliability rating of this SUV is 84/100.

In terms of longevity, the GMC Envoy could easily last 150,000 to 400,000 miles. Proper care and maintenance (including regular oil and fluid changes) is the way to go if you want to prolong the life of your vehicle .

Common GMC Envoy Failures

The GMC Envoy may not have enough reliability information on vehicle review websites, but owners have shared their issues with this SUV. Below are some of the top common GMC Envoy failures:

1- Leak in the exhaust pipe

A couple of 2009 GMC Envoy owners have reported hearing loud exhaust leak sounds from their SUVs. According to one of the reports, the noise was the result of a cracked exhaust manifold . The exhaust manifold replacement cost the owners about $500. Affected owners said they encountered this issue around 80,000 miles.

GMC has published a Technical Service Bulletin (TSB) to provide more information on the intake manifold and how to fix this issue. TSB #000601026I is the latest version of the bulletin and was published in August 2016.

2- Problems with the ignition switch

Owners of 2008 GMC Envoys have trouble turning the ignition switch on. Most of the reports say that this problem occurs repeatedly. A couple of owners have even reported running into the problem at least three times in a single year.

The problem reportedly started at 70,000 miles of ownership. These owners paid at least $250 to replace the ignition switch on their SUVs.

GMC published a TSB to address this issue in September 2016. TSB #PIC5491J contains preliminary information for technicians on how to diagnose and fix this fault. At the time of this writing, there are no recalls or investigations into this issue for this specific model year.

3- Indicator failures

This seems like the worst problem on this list. Affected owners of 2004-2007 Envoys shared how they almost got themselves into bad situations due to faulty fuel gauges, speedometer readouts, and temperature gauges.

On average, owners encountered this problem around 75,000 miles, and it cost them at least $400 to fix. Most owners have reported that replacing the entire gauge cluster has fixed the problem .

GMC published TSB #PIC3100F in November 2017 to provide information on how to verify odometer accuracy. This bulletin covers all GMC models from 2000 to 2018. Other than this bulletin, there are no other TSBs or recalls for this issue available online.

However, the US National Highway Traffic and Safety Administration’s (NHTSA) Office of Defects Investigation (ODI) opened an investigation into this issue in June 2010. In addition to 2005 GMC Envoys, this investigation also covered the Chevy Trailblazer, Buick Rainiers and Saab 9-7X vehicles. The case was closed in 2011 and no recall has been issued at the time of writing this post.

4- Excessive oil consumption

Excessive oil consumption is one of the common 2006 GMC Envoy failures, in fact one of the three worst problems. Many owners have reported that they constantly need to top up their oil every 600 miles or so.

According to one owner, there were no leaks or other signs of a problem, but when they checked his SUV, they found that one of the cylinders was already bad . Because the engine was damaged, the affected owners had to pay $4,000 to get the engine replaced.

To help address this issue, GM issued TSB #PIP5163, which was first published in 2013. According to this bulletin, owners claimed their SUVs could have cylinder bore damage, scoring, or out-of-round damage.

This alleged defect is said to cause excessive oil consumption , misfiring, cylinder leaks and blow-by. According to the 2018 version of this document (TSB#PIP5163D), even if a cylinder is suspected of being oversized, GM can only confirm it by checking with an air gauge at the engine plant.

This document also contains inspection procedures for this problem. The 2021 version of this document is not available at the time of writing this article.

So far, there is no recall for the problem of excessive oil consumption. Other than this, the 2006 Envoy has a few recalls for issues like a faulty main power window switch, headlights, airbag sensing system, and power steering hoses.

5- Loss of engine power

Loss of engine power is a common problem with the 2004-2005 GMC Envoy. A bad catalytic converter seemed to be the main cause of the problem for the 2004 models. However, 2005 Envoy owners noticed different symptoms that pointed to different root causes.

One owner said the mechanic told him bad gas was the problem. Another was told the problem was a faulty throttle body and power control module. Another owner had to replace a damaged accelerator pedal module.

Both the 2004 and 2005 Envoy have multiple TSBs listed for this issue. The 2004 and 2005 Envoys only have three recalls each that were the result of NHTSA investigations in the US. Parts involved in these recalls include headlight assemblies, brake lights, turn signals, airbag sensing systems, and windshield urethane adhesives.

A fuel pump module leak issue on 2004 model years was also investigated , but closed because ODI saw actions GM took to mitigate any unreasonable safety risk. As mentioned above, the ODI opened an investigation into the failure of the fuel level gauge system on 2005 GMC Envoys, but this case was closed in 2011.

6- Gas leak and cracked filler neck

Gas leaks are one of the three worst common GMC Envoy failures. It is also known to be the worst problem with the 2003 and 2004 GMC Envoy. Affected owners have reported that their check engine lights came on before they found a crack in their fuel system.

When they went to the dealership for repairs, they found out they had to replace their fuel tank and fuel sending unit. The average cost of repair is at least $1,200.

NHTSA in the US opened an investigation in January 2004 into this issue for 2003 and 2004 model years. NHTSA’s ODI found that the rate of complaints, field reports, and warranty claims was low compared to other recalled vehicles. market. Therefore, the GMC Preliminary Evaluation case #PE04001 was closed and no recalls were issued for both model years.

In addition, NHTSA also opened an investigation (GMC Engineering Analysis EA07009) on the 2004 model year in July 2007, but found that most of the reports were from the US Salt Belt region.

Cracks in the fuel pump module and filler necks were caused by corrosion from road salts , often used to de-ice roads in the area. In lieu of a recall, GM extended the warranty on affected components for 2004 GMC Envoys to 120,000 kilometers. The case was closed in August 2008.

7- Fan malfunction

A number of 2002 GMC Envoy owners have problems with the fans in their SUV. Although this problem is not as serious as all the others on this list, it is still one of the most annoying failures that cause SUV air conditioning to malfunction.

The affected SUVs’ fan motors reportedly only ran on the highest settings, and sometimes the air conditioning didn’t work at all. Owners ran into this problem at about 85,000 miles.

Repairs cost between $60 and $100 and involved replacing the blower motor resistor and, in some cases, the blower itself.

Unfortunately, at the time of writing, many of the TSBs related to this issue are not available. In another vein, the 2002 Envoy has had quite a few NHTSA recalls and investigations.

Some of the parts that had to be recalled include the seat belt assembly, instrument panel cluster, steering column, fuel filter attachment, and air bag. There was also an investigation that led to a recall. It was about the electronically controlled air suspension of the SUV.

To complete

With all the recalls and common problems the GMC Envoy has, it’s understandable that you might be hesitant to buy a used unit. However, as long as you do your research on the model year you like and find a seller you can trust, buying this SUV can be low risk. Just remember to clarify everything with the seller before you seal the deal.

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