2004 GMC
ENVOYProblems & recalls

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.

Recorded closure: Mar 29, 2021

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.

Recorded closure: Aug 28, 2008

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.

Recorded closure: May 6, 2005

Campaign reference in the source: 05V198000

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.

Recorded closure: Nov 4, 2004

Campaign reference in the source: 04V527000