Tank Assembly problems of the 2005 GMC Envoy - part 1

106 problems related to tank assembly have been reported for the 2005 GMC Envoy. The most recently reported issues are listed below.

1 Tank Assembly problem

Failure Date: 12/09/2013

At lees than 1/4 tank of fuel the gas gauge is close, after refueling, the fuel gauge goes way past full and will stay like that until fuel is below 1/4 tank. Last time the truck took 19. 85 gallons in a 20 gallon tank until it started working correctly again. One tank it worked fine and next fill up it was way beyond full again. At the same time when fuel gauge is wrong, the speedometer will be off. Many times freezing at 35mph while traveling 65mph. After many resets of ignition, the speedometer will come back. Also when all of this is happening with the speedometer and fuel gauge, the radio has no audio. Every now and again, the radio will come back and work on one speaker. Most of the time it is out. When weather is warmer, all 3 functions seem to work regularly. Below 50 degrees, all malfunction.

2 Tank Assembly problem

Failure Date: 06/18/2013

Fuel guage sensor 2005 Envoy xl denali. 70153 miles. After fueling the vehicle fuel guage registers empty until about an eighth of a tank has been used then the fuel guage works just fine. Have to disconnect the positive battery terminal for appx. Ten minutes to get the service engine light to stop illuminating. Occurs everytime I fill the vehicle. It causes an innaccurate fuel reading. Turning in to dealer tomorrow 06-19-2013 for repairs. Code produced p0463.

3 Tank Assembly problem

Failure Date: 06/04/2012

2005 GMC Envoy out of the blue my speedometer works intermittently and my gas gauge reads empty with light on even though I have a full tank of gas! additionally the factory speakers work intermittently. This vehicle has electrical issues!.

4 Tank Assembly problem

Failure Date: 04/02/2012

I received a letter from GMC approximately a year ago stating that there was a recall to the fuel gauge on my vehicle. I didn't think anything of it since I had not experienced the issue and the letter stated not to take it to the dealer unless you currently had the problem. As of a week ago the fuel gauge stopped working. I fueled up until the tank was full and the gauge reads as if the tank is empty and the low fuel light is on. In addition the speedometer has is having issues now as well. It sticks at highway speed and then just goes to zero and stays there. If it weren't for my gps I would have no clue what rate of speed I am traveling. I have contacted GMC customer service as well as the dealership and the repair for the fuel gauge will cost me $240 with GMC paying the other half. It seems to me that they were aware that there was an issue before I did so why am I now stuck with the repair bills? why was this not fixed before the vehicle was sold to me since I purchased it used from the dealership? something should be done about this. I should not be held accountable for GMC's errors! in addition there are recalls on the other GMC models for the cluster gauge that affects the speedometer. The Envoy was not included because there were not a sufficient number of complaints. Once again why should I be stuck holding the bag on faulty equipment? what can be done to get this resolved?.

5 Tank Assembly problem

Failure Date: 03/01/2012

2005 GMC Envoy. Attorney writes on behalf of the client in regards to fuel level censor that may wear prematurely the attorney stated his clients vehicle service engine light illuminated and the fuel gauge read empty after filling the tank. Ultimately, the sensor wore out, which caused the fuel gauge to stop working.

6 Tank Assembly problem

Failure Date: 02/06/2012

After filling the tank in my 05 Envoy the gauge reads empty for a while, then goes up and down.

7 Tank Assembly problem

Failure Date: 02/03/2012

Fuel gauge does not work. I will fill up the tank and turn on the car and it reads low fuel and the indicator light comes on. Then I can be driving and it will jump up to past 1/4 tank then slowly go down to e and read low fuel.

8 Tank Assembly problem

Failure Date: 02/01/2012

The fuel sensor on my vehicle swings wildly from empty to full even when the fuel tank has just been filled. This results in the check engine light to constantly be on. I am unable to determine how much gas is in the car due to the faulty sensor. I have checked the internet and this appears to be a widespread problem that has been reported for years. I called gm and they told me that they have known about the problem and will cover 50% of the cost only if I take it to a gm dealer and that my portion of the cost would be between $500 - $600 dollars. They would not cover any of the cost if I take it to my local mechanic. This problem has been known by gm for years and they should have issued a complete recall to repair the defective part(s).

9 Tank Assembly problem

Failure Date: 01/16/2012

The gas gauge on my 2005 GMC Envoy slt has began reading incorrectly. The gauge reads empty even when the tank has fuel in it. After a day or so the tank reads normal, then it begins to fluxuate from correct to empty. Then the check engine light will begin coming on, and will go off again with no resetting.

10 Tank Assembly problem

Failure Date: 01/12/2012

Fuel gauge shows empty when tank is full. It will work again at about half a tank, then when we refuel it will go to empty again. Then it will start to go up to about 1/8 tank, then go back to empty. Sounds like this is a major issue with gm vehicles.

11 Tank Assembly problem

Failure Date: 12/27/2011

I have had a problem in the past with the fuel gauge reading empty continuously as I have read from many other complaints. Recently I experienced a problem with the oil pressure gauge. At first the check engine light appeared intermittently and then the oil pressure gauge dropped to zero, at which time the message in on the lcd reading said "stop engine" and "oil pressure low". I immediately went to my gas station and checked the oil, which was only down a 1/4 tank. My mechanic stopped the car and started it again and the oil pressure gauge reset itself but once I started to drive the car again, the oil pressure dropped. My mechanic believes it is another sensor problem like the fuel sensor but is not completely sure. I only started with this issue today but it is more worrisome to me than keeping track of how much gas should be in my tank. I am curious to know if others have started to experience this problem. I have had the car since it was brand new and have drive 79000 miles. I also had a major issue with the suspension system with I believe is common in this vehicle.

12 Tank Assembly problem

Failure Date: 12/14/2011

After filling fuel tank, sensor went to empty imediately. Chimes activate and fuel gauage reads empty.

13 Tank Assembly problem

Failure Date: 12/03/2011

The gas gauge on my 2005 GMC Envoy has begun reading incorrectly. The gauge reads empty when I fill it with fuel. After a couple of days the tank appears to return to what I believe is a normal reading. Then, on it's own, it will fluxuate dropping to empty, triggering the low fuel light and alarm and then return to it's previous position. At this time, I cannot trust the gauge to be accurate.

14 Tank Assembly problem

Failure Date: 10/10/2011

I noticed that when I filled up the tank the light came on as if the tank was empty. I actually stopped when I was pulling out of the gas station and looked at my receipt and questioned the attendant. The tank was full. The gauge was erratic from then on going from full to empty in a matter of two to three miles and it has been happening regularly. The funny thing was that I just got a letter from GMC advising me of this problem and magnanimously offering to pay for 50% of the cost. I couldn't believe the timing. Thinking it was a minor thing I called the local dealer to set up an appointment and found out that I am facing a minimum of $600. 00 for dropping my gas tank and checking to see what the problem is. Seriously!!!???? when I researched this it appears that this is a rampant problem with these vehicles. Why is this not a recall?? why am I burdened with this ridiculous cost when it is apparent that this is a manufacturing problem. This is a very dangerous situation as a false reading on the gas gauge could make the driver think they have a full tank when in fact it is empty an the vehicle could stall out in the middle of traffic and cause a horrific accident. I would like to add my request for action from GMC to fix this problem immediately at their expense - not the consumers'.

15 Tank Assembly problem

Failure Date: 09/09/2011

"GMC Envoy fuel sensor may fail prematurely". I got this information from gm in a letter. They will pay 1/2 cost to have it replaced if the vehicle is less than 10 years old and has =<120k miles. My vehicle has 148k and is a 2005 model. Gm tells me they will not help me with this problem due to the higher miles. I consider the fact that the fuel sensor may read empty even when full or full when in fact the tank is empty to be a safety hazard. I am asking for your help to have gm recall the affected models and repair at no cost to me or the thousands of others who in fact have the same problem. I have never filed a complaint before and hope that I have provided enough information for the board to take positive action.

16 Tank Assembly problem

Failure Date: 08/24/2011

My 2005 GMC Envoy sl only has 47,000 miles. I experienced dash electronics concerning warning indicator lights ("power train cooloing fan at 46,000 miles") and gas tank level gauage stopped working at 40,000 miles. I have been told that this issue related to an overall sensor problem and will effect the headlights and other safety related issues.

17 Tank Assembly problem

Failure Date: 08/17/2011

Let me start like this. My family including my grandfather always had Chevrolet or GMC cars. I was raised learning how strong they were, smooth driving and extremely comfortable. I bought a chevy trailblazer 2002 in 2006 which I loved, but unfortunately somebody had crashed and after fixing I sold. Next, I decided to buy an Envoy slt v6 2005 with 27kmiles in 2008, which I have until today and I love so much. Smooth drive, comfortable, powerful, great looking, spacious and great engine. As my grandfather used to say, "son always have a normal maintenance and this car will last forever". I never had any serious problem, except now that the fuel sensor level is dead and I have the chime always signalizing low fuel even if I fill out the tank. Well I wait for more than 3 months filling out the tank and tracking the mileage. 2 weeks ago I received a letter from GMC with my VIN number standing that this is a problem that they find out and they are willing to pay 50% of the cost. I did call them in fact to know the authenticity of the letter and they confirm the issue recommending to take to the dealer. I did, and this problem has a cost equivalent of almost a thousand, which with 50% of discount with the letter will be close to five hundred. GMC is avoiding having this paid 100% since it's a recognized and it should be a recall. I refuse to pay for something that it's a manufacturing defect part. My car has 86k miles today and its still with the problem. I called GMC more than 3 times and the answer is always the same "we'll pay 50% of the total cost". This is ridiculous!!! I want this solved. It's a safety issue !!! I want this paid 100%.

18 Tank Assembly problem

Failure Date: 08/07/2011

Fuel gauge started going from full to empty (after filling), and now it pretty much is in the empty position even with the tank full. Vehicle has 79k miles. Low fuel warning lamp and sound are engaged.

19 Tank Assembly problem

Failure Date: 08/01/2011

I purchased this car used with approximately 24,000 miles in 2006. Within a year of purchasing the car the cluster panel (gauges) stopped working. I took the car in to have it checked and was told that there was no recall and that it would cost approximately $700 to repair as the entire cluster panel would have to be remove and replaced. After talking with CO-workers with the same vehicle experiencing the same problem; I later discovered that there had been a recall on this issue but you had to be the first owner of the vehicle. After having the cluster panel repaired, my gas gauge has stopped working and I am told that the entire tank has to be removed for repair and that there has not been a recall on this issue either. The window and door lock system on the front passenger door also is non-operational. This vehicle seems to have several minor electrical issues but I am most disturbed by the fact that after spending the money to have the cluster panel fixed my gas gauge is still not working properly.

20 Tank Assembly problem

Failure Date: 07/18/2011

Faulty fuel gauge. After filling up tank with gas, fuel gauge reads empty. After some driving, fuel gauge indicates a changing level of fuel with the range indicator fluctuating from 0 to ~114 miles left. Usually gauge reads 0 regardless of how much fuel is in the tank, but sometimes it will indicate a higher reading than what the tank actually holds. This issue has caused 1 incident where the vehicle ran out of fuel while the gauge indicated there was still fuel in the tank. I believe the problem to be with the sending unit on the gas tank.

21 Tank Assembly problem

Failure Date: 06/28/2011

The gas tank sensor went out. Lately received a letter from GMC for repair but with 2 criterias. First : vehicle must be under 120. 000 miles and second criteria less than 10 years. My personal situation only applies the 10 years. I talk to gms and GMC in turn says I have deal with the local dealer and local dealer says GMC must authorized the repair. I further investigate the issue that there are many similar situations and GMC knows that it's a defective part. I think it is in danger if I forget to gas up my car.

22 Tank Assembly problem

Failure Date: 06/22/2011

Sitting at a rr crossing awaiting train to pass , my fuel gauge came on that I neede gas even as the tank was over 1/2 full when it happened. Has not read correctly since goes from full to empty and to a 1/4 tank, to 1/8th to 1/2 tank. Does not read accurate has just turned 49000 miles 2005 GMC Envoy.

23 Tank Assembly problem

Failure Date: 06/07/2011

The fuel gauge in my 2005 Envoy xl goes to low fuel anytime after 1/4 tank left. After filling up, it will read low fuel for about 15 miles. It then fluctuates for awhile before settling on what I hope is an accurate reading.

24 Tank Assembly problem

Failure Date: 06/02/2011

I filled my gas tank up to full around 2 months ago. After I was done, I started the vehicle, and noticed the gauge dipped to empty and showed that I was low on fuel. I went in and had the attendant verify that indeed I did have gas dispensed into my tank. The gauge continued to fluctuate for the next few days, and ever since has shown empty to 1/4 or 3/8 of a tank, never showing the same reading for more than a few minutes at a time. I have a family and do worry for their safety. There is no way of knowing truly how much gas is in there at any given moment, and the cost is way to steep to repair. I have spoken to multiple gm dealers and customer service reps, and have found that they like to pretend that this has never happened to anyone before. Very uncooperative. My concern is for myself of course, but also for those purchasing these vehicles used from private parties without being notified of this acute and widespread parts failure, which indeed must be defective if it is happening to so many. Safety is of course the biggest issue here, and gm should take note.

25 Tank Assembly problem

Failure Date: 06/01/2011

When I fill the gas tank, the gauge goes to empty and stays there for a while until it finally seems to correct itself but I am unsure if it is correct at all times and afraid it will show there is gas and run out. I have seen where several of Envoy owners are having the same issue. I feel gm should make correct these sensors.

26 Tank Assembly problem

Failure Date: 06/01/2011

I have a 2005 GMC Envoy. Within the last few weeks my gas guage tells me I have no gas even after the fact I just filled up. I even tried turning the car off and on hoping it would reset itself, but no. So til this day my gas guage say empty. I'm the orginal owner of the car, I bought it new, no accident. I also taken to the autoshop and I when I took it in the gas guage when up alittle but then when I turned car off it when back to showing empty. It has continued to get worse. It now fluctuates up and down, but if tank was recently filled, will remain on e for a while. I feel this is not safe for me to drive like this because I never know if I have gas or not.

27 Tank Assembly problem

Failure Date: 05/15/2011

I have a 2005 GMC Envoy and the gas light and fuel tank gauge are malfunctioning. When we fill up with gas the empty gas remains on for several minutes and then only moves to 1/4 of a full tank. Later it will move up, but will driving it will just drop to empty.

28 Tank Assembly problem

Failure Date: 05/12/2011

Fuel gauge does not go above 1/8 tank. Speedometer "sticks" usually at highway speed and when stopped does not return to zero then when vehicle is moving again the new speed is accumulating on "stuck" speed. Sometimes speedometer "sticks" before reaching steady speed and when vehicle is stopped the reading is below zero in this scenario when the vehicle is moving again the "registered" speed is below actual speed. As I drive 1,000 miles a week, it is quite important to know how much fuel I have in my tank and of course how fast I am traveling.

29 Tank Assembly problem

Failure Date: 05/02/2011

Please add our vehicle with a gas gauge that is faulty. Condition began last fall and we just escaped running out of gas the first time it happened. Fuel light indicates that the fuel is empty or near empty when in reality it is full or near full. Just the opposite happens when the light indicates fuel is in the tank when in reality, it is almost empty. Our local mechanic was not sure what the problem was the repair could approach $150. We now refuel when the trip odometer hits 300 or so miles.

30 Tank Assembly problem

Failure Date: 05/01/2011

The fuel gauge stopped working. The fuel gauge reads empty when the fuel tank is full. The check engine light is on.

31 Tank Assembly problem

Failure Date: 05/01/2011

The fuel gauge on my 2005 GMC Envoy failed to correctly report the quantity of gas in the tank starting at about 30,000 miles. It always reports a value that I know is wildly inaccurate, and even sets off the low fuel alarm when I know the tank is nearly full. I stopped relying on the gas gauge a long time ago, because that would inevitably lead to the vehicle running out of fuel causing vehicle stall with no restart, with obvious safety implications. Instead, I fuel the vehicle on the basis of number of miles driven, an inherently flawed method with higher probability of failure. My dealer has advised me that repair would cost over $400.

32 Tank Assembly problem

Failure Date: 04/30/2011

Purchased new from dealer 2005 GMC Envoy - fuel gauge reads empty - sometimes - it will tell you have more gas - most times it reads empty. I ran out of fuel on sat 4/30/11 - stuck going up a hilled entrace into a mall. There is no accurate way to tell how much fuel left in tank. Please force a recall for GMC instrument panel problems. Issue is widespread.

33 Tank Assembly problem

Failure Date: 04/22/2011

Immediately after filling gas tank before heading out of town on 4/22/11, fuel gauge registered empty. Gauge has been acting erratically for the past week now. News report of NHTSA investigation made me aware that I could report this somewhere. Oil pressure gauge has also been acting similarly erratic, starting a few days before fuel gauge began malfunctioning.

34 Tank Assembly problem

Failure Date: 04/17/2011

Fuel gauge never reads correctly even after tank is fuel gauge doesnt register anymore than half a tank when moving, anytime vehicle comes to a complete stop the gauge goes to empty and the low fuel light comes on. Also gauge never reads the same at any time very inconsistant.

35 Tank Assembly problem

Failure Date: 04/12/2011

The gas gauge started failing. It started marking random fuel values which were completely incorrect. It would mark half a tank when it was full. It would randomly jump to different setting after each start. And finally it got stuck on empty with the empty light on.



Fuel Economy of Envoy Vehicles
Envoy Service Bulletins
Envoy Safety Recalls
Envoy Defect Investigations