Summary
The GMC Envoy has 31 recalls spanning the 1998–2007 model years, with the most serious recent issue being a driver's door module on 2006–2007 models where fluid intrusion causes corrosion that can short-circuit the board and start a fire, even with the vehicle parked and turned off.
The 2005 model year has a windshield bonding defect where the urethane adhesive may not have fully cured against the body, meaning the windshield can separate in a crash and leave occupants less protected. There is also a 2005 windshield wiper module that can trap water, causing wipers to stop working mid-drive, run continuously, or fail to activate at all, reducing visibility in rain.
The 2002 model year carries the heaviest concentration of issues. On 4WD-equipped examples, a cracked range shift collar in the transfer case can fracture completely, causing the vehicle to lose forward and reverse drive and preventing it from holding in Park, which risks a rollaway. A separate transfer case control module calibration issue on 2002 4WD models can also prevent full gear engagement, again allowing the vehicle to roll from a parked position. The front lower control arm brackets on 2002 models can fracture and allow the control arm to separate from the frame entirely, resulting in sudden loss of steering and directional control. The air suspension system on 2002 models can produce an electrical spike that stalls the engine while driving or damages the powertrain control module so the vehicle will not restart. The fuel filter fitting on 2002 models can disconnect, spilling fuel onto the ground and creating a fire risk, or cutting fuel supply while driving and eliminating power steering assist. The 2002 driver and front passenger seatbelt retractors may have inoperative sensors that prevent the belt from restraining occupants properly in a crash. Also on 2002 models, the center console armrest latch can release under crash loads, sending the lid or stored contents into the cabin.
The 2003 model year has a scored left-front brake pipe that can fracture and immediately reduce front braking performance. Turn signal and hazard flashers on 2003 models can illuminate steadily instead of flashing, or activate on both sides when only one side is intended, making it difficult for surrounding drivers to read the vehicle's intentions. The 2003 automatic transmission has a mechanical override that allows the ignition key to be removed with the shifter out of Park.
Going back to the earliest production, the 1999 model has a console armrest latch that can release under crash loads, similar to the 2002 issue. The 1998 model year has daytime running lights that remain on when the turn signal activates rather than dimming, making it harder for oncoming drivers to see the turn signal. There is also a 1998 console armrest cam latch that can release under crash forces.
