Manifold/header/muffler/tail Pipe problems of the 2002 Chevrolet 1500

Two problems related to manifold/header/muffler/tail pipe have been reported for the 2002 Chevrolet 1500. The most recently reported issues are listed below.

1 Manifold/header/muffler/tail Pipe problem

Failure Date: 07/01/2013

Front manifold bolt has broken on driver side causing a leak, research has shown that this is a big problem with gm pickups made during these years. It is a very costly repair and there are literally thousands of other gm owners with the same problem. There should be a recall on this defective part. It is a dangerous problem, leaking carbon monoxide thru the and into the driver and passenger area. There should be a recall by gm to fix this problem.

2 Manifold/header/muffler/tail Pipe problem

Failure Date: 02/09/2012

Exhaust manifold bolts breaking off leaving studs in the heads (4) my late 2002 chevy z71 developed an exhaust leak and the catalytic converter started banging at idle or after parked. Engine has black exhaust on the head where we found the main leak. So, carbon monoxide has been coming into the cab and the engine compartment seems hotter than normal. When checking into the issue, I found every truck in our company fleet has this same issue and our associates that have personal trucks driving to work checked theirs and they also have the same issue. From 1999 thru 2008 years. When contacting our local chevy dealer, they advised they had never seen or heard of any issues like this. I find that hard to believe. Every person I mention this to, checks their truck and has the same issues with the broken bolts. There is definitely a problem with the exhaust manifold contracting and expanding too much- cheap steel attached to aluminum heads appear on all of the v-8 truck engines. Please look into this as a safety issue with heat and carbon monoxide as well as the costs to repair.


Other Engine And Engine Cooling related problems of the 2002 Chevrolet 1500



1500 Service Bulletins
1500 Safety Recalls
1500 Defect Investigations