Manifold/header/muffler/tail Pipe Problems of Chevrolet 1500

Chevrolet 1500 owners have reported 15 problems related to manifold/header/muffler/tail pipe (under the engine and engine cooling category). The most recently reported issues are listed below.

1 Manifold/header/muffler/tail Pipe problem of the 2003 Chevrolet 1500

Failure Date: 05/04/2014

The bolts are broken off in the manifold, after checking you-tube I found this is a problem the gm has chosen to ignore.

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2 Manifold/header/muffler/tail Pipe problem of the 2001 Chevrolet 1500

Failure Date: 09/29/2013

Two of the factory exhaust manifold bolts are broken on the drivers side of the engine, the back two nearest the fire wall. There is an exhaust leak due to the factory exhaust manifold bolts breaking off, and the manifold is leaking exhaust which is very close to the firewall material which I am worried that might catch on fire. Gm should have a recall on these exhaust manifold bolts on silverados to fix and repair them.

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3 Manifold/header/muffler/tail Pipe problem of the 2003 Chevrolet 1500

Failure Date: 07/15/2013

Inspection revealed that the heads on several exhaust manifold bolts had broken off. Reportedly, this has been a very common defect in gm p/u trucks and SUV's. From what some technicians have said, gm used substandard bolts for this application, and that they simply cannot bear up under the heat from manifolds. Many complaints have been filed by vehicle owners, but gm refuses to acknowledge the problem and institute a safety recall for this potentially serious safety issue. The repair of this problem is very costly and can cause (and has caused) additional problems with other vehicle components.

4 Manifold/header/muffler/tail Pipe problem of the 2002 Chevrolet 1500

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.

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5 Manifold/header/muffler/tail Pipe problem of the 1999 Chevrolet 1500

Failure Date: 09/01/2012

Exhaust manifold bolts breaking by themselves, the heads have fallen off leading to exhaust leaking!.

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6 Manifold/header/muffler/tail Pipe problem of the 2000 Chevrolet 1500

Failure Date: 03/01/2012

Exhaust manifold bolts broke off resulting in pinging noise. My mechanic verified the broken bolts and told me this could lead to other more serious problems including possible fire. He also suggested I should contact a gm dealer to see if there was a recall for this problem. I have been driving for more than 50 years and I have never had exhaust manifold bolts just break off.

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7 Manifold/header/muffler/tail Pipe problem of the 2003 Chevrolet 1500

Failure Date: 03/01/2012

I purchased this vehicle used on March 1 2013 didn't noticed any problems except a slight engine noise. I thought the engine noise was tapping valves, because I was told the truck was not on the road for about a year. When I changed the oil for the first time I noticed that the rear manifold bolt was missing, looked at the other side, that was missing also. I heard I could e-mail you to report a problem so I did.

8 Manifold/header/muffler/tail Pipe problem of the 2001 Chevrolet 1500

Failure Date: 02/10/2012

Exhaust manifold bolts breaking off leaving studs in the heads gm is not standing behind this issue. This is causing CO release, high heat in the engine compartment, noise, and an expense that I should not pay for. Some states are not accepting these vehicles now for not meeting the emission standards please look in to this. It is a safety hazard.

9 Manifold/header/muffler/tail Pipe problem of the 2002 Chevrolet 1500

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.

10 Manifold/header/muffler/tail Pipe problem of the 2003 Chevrolet 1500

Failure Date: 09/01/2011

The bolt heads on the exaust manifold are snapping off causing an exaust leak and a possible emission failure.

11 Manifold/header/muffler/tail Pipe problem of the 2004 Chevrolet 1500

Failure Date: 08/31/2011

I own a 2004 Chevrolet silverado 1500 4x4. I have a broken rear exhaust manifold bolt on the left side of my 5. 3 v8. I hear this is an extremely common problem. My local dealer wants $1,600 to fix it because you do need to pull the aluminum head to repair it!! I completely agree with the head needing to be pulled, but I believe that gm needs to step up and fix this extremely common and ongoing problem. It is definitely a manufacturer defect!!.

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12 Manifold/header/muffler/tail Pipe problem of the 1997 Chevrolet 1500

Failure Date: 04/15/2004

97 Chevrolet truck 50000 miles intake gasket failure.

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13 Manifold/header/muffler/tail Pipe problem of the 1999 Chevrolet 1500

Failure Date: 12/24/2002

I am writing to convey my extreme disappointment in the quality of Chevrolet vehicles. We own a 1999 Chevrolet, tahoe which we bought new. On December 24, 2002, our transmission went out at 103000 miles. As a result, we had to have a new transmission installed at a cost of $2,646. 72 plus the cost of renting a vehicle. We drive about 25,000 miles per year. We do not do any towing, we do not use four-wheel drive except in the winter, and we take good care of our vehicle. Since this incident, this transmission we had replaced has failed again, fortunately about 2000 prior to its 50000 mile warranty. I am still trying to understand how this is happening. We do not abuse our vehicle and we drive like any regular person does. Oh yes, poor engineering. Furthermore, about a year ago, we had to replace the intake manifold gasket on our engine which cost us $700. Not only that, when we took the tahoe to have the 2nd transmission fixed, I asked if our cracked door handle was the result of a break-in. The technician chuckled and said that was common. He even had the audacity to blame it on the consumer for not using the door handle properly actually showing us how you had to lift and. Seems to me that this is poor engineering. I even went so far as to contact several Chevrolet dealerships who unanimously agreed that a transmission on these vehicles should last at least 200,000 if not the life of the vehicle. I?m not sure what anyone else expects from their vehicles, but we do not expect a major component, like part of the engine, to blow at such low mileage. I did make my voice heard by writing a letter for the 1st transmission they put in, but all they could offer me was $1000 loyalty voucher towards the purchase of a new GMC product. If they can't make good on my first GMC vehicle, then why would I buy another? in closing, I need to make my voice heard so people don't buy gm products.

14 Manifold/header/muffler/tail Pipe problem of the 1996 Chevrolet 1500

Failure Date: 11/20/2002

The intake manifold had two different metals which did not hold the gaskets properly.

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15 Manifold/header/muffler/tail Pipe problem of the 1996 Chevrolet 1500

Failure Date: 11/20/2002

The intake manifold had two different metals which di not hold the gaskets properly.


Other Common Engine And Engine Cooling related problems of Chevrolet 1500


1500 Service Bulletins
1500 Safety Recalls
1500 Defect Investigations