2004 GMC Envoy

The 2004 GMC Envoy is a mid-size SUV known for its comfortable ride and available four-wheel drive. Engine options included a 4.2L Inline-6, producing 275 horsepower and 275 lb-ft of torque, and a 5.3L V8, producing 302 horsepower and 330 lb-ft of torque. Both engines were paired with a 4L60-E four-speed automatic transmission. Many owners appreciate the Envoy’s spacious interior and towing capability, while common complaints include fuel economy, electrical issues, and certain engine and transmission problems specific to the year and powertrain.

Engine

4.2L Inline-6

• Rough Idle/Stalling
  • Description/Symptoms: The engine may experience a rough idle, stall unexpectedly, or hesitate during acceleration. This is a common issue.
  • Solution: Cleaning or replacing the throttle body is a common solution. A PCM flash/reprogramming may also be necessary.
  • Estimated Cost to Fix: $100 - $300+
  • Recalls: None Found
• Coolant Loss/Overheating
  • Description/Symptoms: Coolant leaks, often from the water pump or thermostat housing. This can lead to overheating.
  • Solution: Replace the leaking component (water pump, thermostat housing, hoses).
  • Estimated Cost to Fix: $150 - $500+
  • Recalls: None Found
• Cam Actuator Failure
  • Description/Symptoms: The engine is hard to start or makes a ticking or rattling noise that gets louder as the engine heats up.
  • Solution: Remove and replace the cam actuator.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

5.3L V8

• Oil Consumption
  • Description/Symptoms: Excessive oil consumption, requiring frequent top-offs.
  • Solution: There is no definitive fix. Some owners have tried using thicker oil or replacing valve stem seals, but results vary.
  • Estimated Cost to Fix: $200 - $1000+ (depending on the approach)
  • Recalls: None Found
• Piston Slap
  • Description/Symptoms: A noticeable knocking sound, especially when the engine is cold, due to piston movement within the cylinder.
  • Solution: Often considered a characteristic of the engine and not necessarily a sign of impending failure. No cost-effective solution.
  • Estimated Cost to Fix: Can be expensive, but often left unfixed.
  • Recalls: None Found

Transmission

4L60-E (Both Engine Options)

• Harsh Shifting/Slipping
  • Description/Symptoms: The transmission may shift harshly between gears or slip during acceleration.
  • Solution: A transmission flush and filter change may temporarily alleviate the issue, but often a rebuild or replacement is needed.
  • Estimated Cost to Fix: $150 - $300+ (for flush); $1500 - $3500+ (for rebuild/replacement)
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: The transmission vibrates heavily, especially at low speeds, and fuel efficiency may decrease.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found

Suspension

• Air Suspension Compressor Failure (If Equipped)
  • Description/Symptoms: The rear of the vehicle sags, the ride becomes rough, and a warning light illuminates.
  • Solution: Replace the air suspension compressor.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found
• Front Suspension Ball Joint Failure
  • Description/Symptoms: Clunking or squeaking sounds from the front suspension, loose steering, uneven tire wear.
  • Solution: Replace worn ball joints
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Electrical

• Instrument Cluster Failure
  • Description/Symptoms: Gauges may stop working or display incorrect readings. This is a very common problem.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $150 - $500+
  • Recalls: None Found
• Driver Door Module Failure
  • Description/Symptoms: Power windows, door locks, and/or mirrors may stop functioning.
  • Solution: Replace the driver door module.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Transfer Case Encoder Motor Failure (4WD Models)
  • Description/Symptoms: Difficulty shifting between 2WD and 4WD, or the vehicle gets stuck in one mode. Service 4WD light is on.
  • Solution: Replace the transfer case encoder motor.
  • Estimated Cost to Fix: $250 - $700+
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust on rocker panels, rear wheel wells, and around door seams.
  • Solution: Rust repair or panel replacement.
  • Estimated Cost to Fix: $300 - $2000+ (depending on severity)
  • Recalls: None Found

Interior

• HVAC Actuator Failure
  • Description/Symptoms: The HVAC system blows hot air on one side and cold on the other or only blows air out of certain vents.
  • Solution: Replace the faulty HVAC actuator.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found
• Sunroof Issues
  • Description/Symptoms: Sunroof may leak, get stuck, or make excessive noise.
  • Solution: Repair or replace the sunroof assembly.
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found

Summary

The 2004 GMC Envoy, while generally a comfortable and capable SUV, has several common issues owners should be aware of. Electrical problems and certain engine/transmission issues, particularly with the 4.2L Inline-6, are prevalent. Suspension issues, especially with the air suspension system if equipped, can also be costly. The severity of these issues ranges from minor inconveniences to major repairs. The estimated costs vary widely depending on the specific problem and the extent of the damage, but owners should be prepared for potential repair bills ranging from a few hundred to several thousand dollars over the vehicle’s lifespan.