Body Problems of GMC Envoy - part 1

GMC Envoy owners have reported 65 problems related to body (under the structure category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of GMC Envoy based on all problems reported for the Envoy.

1 Body problem of the 2003 GMC Envoy

Failure Date: 08/09/2024

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.

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2 Body problem of the 2003 GMC Envoy

Failure Date: 09/23/2021

Rear door will not open. Window works but door handles inside and outside will not unlock door to open.

3 Body problem of the 2003 GMC Envoy

Failure Date: 07/01/2021

1. The air bag dummy light is on 2. The relay switch keeps going bad on my regular headlights, but the brights will turn on 3. Rear driver side door popped open on the highway while driving with my 12 year old nephew in the backseat. Will not latch shut.

4 Body problem of the 2005 GMC Envoy

Failure Date: 06/29/2021

This SUV made a loud sound, began to drift, in the rear, at hwy speeds before it tipped over and began to roll, ejecting my two minor sons from the passenger cab before it eventually landed on its side. The roof was molded in a triangular shape, preventing it from resting on the roof as it tilted back onto inside and remains after the last roll the triangular shape was created in the metal after the stabilizing structures gave way almost immediately providing possibly no protection to the patrons inside the carrier cab of SUV. Demonstrating its inability protect its occupants.

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5 Body problem of the 2003 GMC Envoy

Failure Date: 04/23/2020

My wife was sitting in the backseat and the back door flew open on the highway. I have also noticed the other back door is not clicking shut and this is a very dangerous situation.

6 Body problem of the 2002 GMC Envoy

Failure Date: 01/26/2020

The front driver side door has no power. The rear passenger door will not open or unlock. The rear driver side door will not latch and stay shut. This all happened when I was getting my kids in the car and now I can't use the car because my kids could fall out. In the other vehicles it was the faulty latch. This happened to other vehicles of the same year and model. Number 05v494000.

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7 Body problem of the 2002 GMC Envoy

Failure Date: 07/22/2019

I was in an accident and hit on broadside on the passenger side and driver front corner. The air bags did not go off. They say service soon. The seat belt hurt me as well. It did not lock. I was injured with a torn labrum, back and neck injuries. Head too. I was moving and I was hit on the drivers side and then pushed into another car. I was on a city street. 14 mile near mount 7-22.

8 Body problem of the 2005 GMC Envoy

Failure Date: 05/10/2019

Parked vehicle in the garage and went in the house. Next morning went to use vehicle and found that the rear hatch glass had exploded. Glass everywhere. The vehicle had not been moved for over 12 hours. Have called to have glass replaced but have since discovered that this is a common issue with these types of vehicles. Now am concerned that it will happen again. Major concern is it will happen again while driving and have my grand children in the back seat and get injured from flying glass.

9 Body problem of the 2005 GMC Envoy

Failure Date: 02/11/2019

Front windshield leaks and rubber/sealant is weak in spots.

10 Body problem of the 2005 GMC Envoy

Failure Date: 01/15/2019

~tl- the contact owns a 2005 GMC Envoy . The contact stated while driving 30 mph, the door would automatically unlatch and locked on its own. The contact stated no warning light was illuminated prior to door opening. The contact stated that the failure would also occurred when vehicle would be revered , the contact stated would hear a abnormal noise. The contact was able to resumed vehicle back to normal, however the failure recurred. The contact stated that their failure related to NHTSA campaign number:15v599000 (visibility). The contact stated a two local dealer was contacted however, no assistance was offered. The contact stated the vehicle was taken to independent mechanic where it was diagnosed with needing to be replaced driver macadam door. The vehicle had not been repaired as of yet. The manufacturer had been informed of failure,and stated that the recall associated to the year 2006 and 2007. The failure mileage was unknown.

11 Body problem of the 2003 GMC Envoy

Failure Date: 01/02/2019

We have been told by two different repair garages that the frame of the vehicle is totally rusted and dangerous. We have 150,000 miles on the vehicle.

12 Body problem of the 2003 GMC Envoy

Failure Date: 10/08/2018

2003 GMC Envoy. . . The rear passenger side door will not latch . . . The door opened doing about 30 mph.

13 Body problem of the 2003 GMC Envoy

Failure Date: 10/08/2018

2003 GMC Envoy . . . The rear driver side door will not latch . . . The door opened while in motion doing about 30 mph.

14 Body problem of the 2006 GMC Envoy

Failure Date: 08/21/2018

On highway us-31 in muskegon county michigan, vehicle (envoy) was at almost a complete stop for a vehicle stopped ahead when struck from behind by another vehicle travelling at 70+ mph. The Envoy was then pushed into the vehicle in front of the Envoy. The Envoy suffered major rear end damage and severe front end damage. None of the front airbags deployed. Both front driver and passenger seatbelts did not restrain. The seatbelts stretched out to their limit. Both front driver's seat and passenger seat twisted inwards toward the console. Severe bodily injuries occurred. On 08/23/2018, GMC was made aware of this. A case was opened. The event data recorder was recovered by GMC. The edr showed the impact velocity, non-deployment of airbags and non-restraint of seatbelts. GMC then closed the case stating that because there was no traumatic brain injury, there would be no further investigation or compensation. The 2006 GMC Envoy was deemed a total loss by the auto insurer.

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15 Body problem of the 2007 GMC Envoy

Failure Date: 06/20/2018

Tl � the contact owns a 2007 GMC Envoy. The contact stated that both low beams and the daytime running lamps had gone off intermittently and the check engine indicator illuminated. The contact stated it had exhibited the same symptoms as TSB: 4t1241. The vehicle was taken to an independent mechanic who informed of the TSB, but the vehicle was not repaired. The manufacturer was notified and informed the contact that the warranty had expired. The failure mileage was approximately 109,000. Jc.

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16 Body problem of the 2003 GMC Envoy

Failure Date: 01/09/2018

Tl the contact owns a 2003 GMC Envoy. While driving approximately 25 mph, the front end of the vehicle fractured. The vehicle was towed to a local dealer (robertson's GMC truck, 2680 cranberry hwy, wareham, MA 02571) where it was diagnosed that the frame assembly needed to be replaced. The vehicle was not repaired. The manufacturer was notified and did not assist. The approximate failure mileage was 90,000. The VIN was not available.

17 Body problem of the 2003 GMC Envoy

Failure Date: 01/08/2018

We purchased our 2003 GMC Envoy xl sle 8 cylinder brand new at alden Buick in fairhaven, mass in July 2003; for the past 3 years we had it serviced at robertsson's GMC 2680 cranberry highway, wareham, mass. 02571,508-291-0044. We had it reconditioned at this dealership last year, spending $4000. 00; we had it inspected at this dealership with the massachusetts vehicle check; it passed the front end check and frame check on 8/4/17. I was driving the vehicle in late December, and hit several deep potholes caused by an ice storm; shortly thereafter I lost steering control of the vehicle. I had it towed to alden Buick/GMC in fairhaven, mass. To be told that the entire frame had collapsed due to extensive corrosion and rust. I had it towed to robertson's GMC in wareham and filed a claim with commerce ins. Co. To hopefully cover the damage to the frame; commerce denied the claim stating"the frame assembly was severely rotted and this extensive rot allowed the right front control arm to break awayfrom the mounting point on the frame rail. GMC issued a technical service bulletin stating that some Envoy models suffered from extensive frame corrosion. Why did robertson's GMC pass the vehicle on the safety check, and why was I not informed of the vehicle's frame corrosion before I spent the $4000. 00 reconditioning it? why is frame check and front end check listed as pass on my vehicle when this corrosion and rust was present at time of insspection? fortunately neither I nor any of my family members were injured while driving/riding in this vehicle.

18 Body problem of the 2003 GMC Envoy

Failure Date: 01/05/2018

Driver door will lock and unlock electronically but if you try to unlock door manually it does not unlock. If car crashes person could get trapped if car is on fire could cause a death if no power to electronic locks.

19 Body problem of the 2004 GMC Envoy

Failure Date: 09/01/2017

The contact owns a 2004 GMC Envoy. While the vehicle was stationary, the exhaust manifold fractured and the heat from the exhaust manifold damaged the frame of the vehicle. The contact stated that the failure caused severe rust and corrosion. In addition, the contact stated that there were holes in the frame. A dealer was not made aware of the failure. The manufacturer stated that the failure was not safety related and there were no recalls on the vehicle. The failure mileage was 136,000.

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20 Body problem of the 2003 GMC Envoy

Failure Date: 07/16/2017

The rear passenger door stop closing . . . . The latch is broken . . . They had a recall on this in 2005 but claim it's close now what can I do?.

21 Body problem of the 2004 GMC Envoy

Failure Date: 05/18/2017

The rear lift gate jams. After reviewing several blogs, this appears to be a popular defect.

22 Body problem of the 2004 GMC Envoy

Failure Date: 04/06/2017

Back window exploded - no contact - not moving. It was parked on the side of the road, nice day, no more then +5.

23 Body problem of the 2002 GMC Envoy

Failure Date: 02/24/2017

There is a large hole in the passenger side front frame. Rusted right through and is unsafe.

24 Body problem of the 2005 GMC Envoy

Failure Date: 08/22/2016

I had three cars in front of me stopped. I did not see any breakl lights and I hit the car in front of me pushing the other cars to hit each other. My front end of my car was severely damaged bad enough to damage the radiator and destroy my ac unit. I'm not sure what else was damaged. It sent the person in front of me and myself to the emergency room. " my air bags did not deploy ". My vehicle was moving on a city street.

25 Body problem of the 2003 GMC Envoy

Failure Date: 04/19/2016

The rear glass on the lift gate completely shattered/exploded while in garage. The car was stationary.

26 Body problem of the 2004 GMC Envoy

Failure Date: 02/19/2016

My GMC Envoy was parked unattended in my driveway directly next to my house. My sons and I were in the backyard playing when my oldest son went to retrieve his ball from the driveway. He came back screaming mom your truck is on fire. I immediately ran over to see the truck full of fire and smoke. I called 911. The truck damage was already done before the firefighters arrived. It appeared to come from the driver side window area. After doing some research I learned a lot of GMC trucks had recalls on certain parts that could put the vehicle at risk for a for setting it's self on fire. I never received any information on recalls for the window switch or was aware of the national recall until I looked into it the evening of the fire. I strongly believe the window switch is what caused the fire. It had to be a defective product made by the manufacturing company.

27 Body problem of the 2003 GMC Envoy

Failure Date: 12/11/2015

I took vehicle to GMC dealer for an unrelated gm special service program and upon removal of the fuel tank, they found extensive rust-through adjacent to where the tank mounts to the frame. They said the "vehicle is not safe to be driven" yet it has only 100,000 miles and its exterior appears almost like-new. Dealer feels the design of the tank being mounted against the frame caused road salt, etc to get trapped where it cannot be cleaned out by undercarriage car washes. I recently contacted GMC but my complaint has not been resolved to my satisfaction. I suspect there are thousands of Envoy/trailblazer (xl) models still on the road with this hidden "cancer".

28 Body problem of the 2004 GMC Envoy

Failure Date: 10/22/2015

Vehicle was being driving approximately at 55 mph. Engine loss power, gas pedal lost resistance and went all the way down to the floor board. Vehicle was pulled over to the side of the road and engine was stalled and all the dash lights were flashing one and off. Engine started to have white smoke coming from under the hood. After a few minutes, the white smoke turned into black smoke and the engine caught on fire. Vehicle was engulfed in flames after a few minutes.

29 Body problem of the 2004 GMC Envoy

Failure Date: 09/09/2015

Tl-the contact owns a 2004 GMC Envoy. The contact stated that while the vehicle was at an independent mechanic for the gear shifter replacement due to corrosion, the vehicle subframe was also found corroded. The mechanic advised the contact that the vehicle was unsafe to drive. The manufacturer was made aware of the failure. The vehicle was not repaired. The VIN was not available. The failure mileage was 100,398. Li.

30 Body problem of the 2003 GMC Envoy

Failure Date: 08/24/2015

Tl-the contact owns a 2003 GMC Envoy. The contact stated that after filling the gas tank the vehicle was driven home an strong gas odor was present. The contact crawled under the vehicle an d noticed the gas tank leaking gas. The vehicle was not taken to a dealer or an independent mechanic for a diagnosis. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 120,000. Bp.

31 Body problem of the 2004 GMC Envoy

Failure Date: 08/06/2015

Tl-the contact owns a 2004 GMC Envoy. The contact stated that the vehicle was idle when he noticed a strong fuel smell. The contact noticed the fuel was leaking out of the fuel tank. The contact drove the vehicle to an independent mechanic and the diagnosis was that the fuel tank was rupture and needed the entire fuel tank needed replacement along with the fuel pump and the fuel lines. The vehicle was not repaired because there were no parts available. The manufacturer was notified of the failure. The approximate failure mileage was 168,000. Bp.

32 Body problem of the 2003 GMC Envoy

Failure Date: 07/22/2015

I was in a mva July 22, 2015 I was tboned on the drivers side and the went headon with a light pole and my airbags never deployed. I had many problems with the electrical in the truck since I purchased the truck. It was an as is with no warranty and I wasnt given any knowledge of problems or recalls. I suffered extensive injuries to my body and my truck was a total loss $10000 in damages to the vehicle.

33 Body problem of the 2003 GMC Envoy

Failure Date: 03/28/2015

The rear door closure on the passenger side flung open upon entering the on ramp for the highway. This vehicle now has two doors that will not latch, due to a manufacturing problem and recall. The dealership refuses to replace stating that the repair for the recall already took place, but has not. . .

34 Body problem of the 2006 GMC Envoy

Failure Date: 01/17/2015

I was pulling up to park in a parking lot. I had total break failure. The electronic safety features failed- and there was no stopping the Envoy. I slid up the curb and into the building. The mechanic that repaired the Envoy has a written report of the safety systems getting stuck half opened and the break lines breaking and there wasn't any fluid in system.

35 Body problem of the 2005 GMC Envoy

Failure Date: 10/29/2014

While driving my Envoy rear door opened up on the highway while driving. I pulled over and tried to close it. It wouldn't close, I had to use a bungy cord to keep it closed.



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