Four problems related to manifold/header/muffler/tail pipe have been reported for the 2002 Chevrolet Silverado. The most recently reported issues are listed below.
The contact owns a 2002 Chevrolet Silverado. The contact stated that while driving, the engine began making a clicking noise. The contact noticed that one exhaust manifold bolt was broken. The vehicle was taken to a local mechanic who advised that two exhaust manifold bolts were fractured. The contact stated that if the vehicle continued to be driven, the catalytic converter would be damaged. The failure recurred because the bolts were defective. The manufacturer was not made aware of the failure. The current and failure mileage was 69,000.
Exhaust manifold bolts breaking leaving studs in the heads, heating up engine compartments, releases carbon monoxide, affects O2 sensor and catalytic converter. Will not pass emissions in some states. Gm not standing behind this 1999-2008 issue. It is a safety issue and is expensive to fix. Gm mechanics denying any such issues. Please check- in to this. Our whole fleet and our personal trucks affected by this.
The contact stated the exhaust manifold warped and caused the studs to snap off. This could cause the exhaust to leak on a cold start. The vehicle was taken to the dealership, but has not yet been repaired. The contact's son-in-law discovered this problem after inspecting the vehicle because he had the same problem with his vehicle. He stated the original studs were too small, and the new studs were bigger. Left and right exhaust manifold bolts broke and were replaced.
While driving under normal driving condition, no bump or obstacle on the road exhaust system separated and dropped, but stayed attached to its structure. The muffler dangled. The cause of the failure was unknown because the vehicle wasn't been inspected by a dealership nor mechanic.