Four problems related to manifold/header/muffler/tail pipe have been reported for the 2004 Chevrolet Suburban. The most recently reported issues are listed below.
Exhust manifold leak check engine light on bolts broken on exhust manifold.
The rear exhaust manifold bolts on both the driver's side and passenger side are broke and now the vehicle has an exhaust leak.
2004 chevy Suburban exhaust system produces noise at idle ;driving;and after shut down. Gm claims noise (popping) is from muffler heat shield expansion and contraction. TSB to correct noise (modifying heat shield) is ineffective. In 2004 motor magazine reported gm acknowledged the noise came from trapped water inside the muffler. The water turns to super heated steam and produces a pop or bang inside the muffler. Gm will not replace the muffler as the problem goes back to 2000 model year. Moreover people ask what that strange noise is from my Suburban, I tell them a defective muffler.
Vehicle had an odor that smelled like antifreeze. Consumer and all of her family members and friends became ill after riding in the vehicle. They had headaches/burning eyes/numbness, and sore throats. The problem was reported, and the manufacturer stated nothing was wrong with the vehicle, however consumer was told that prior to the purchase of the vehicle there was an antifreeze spill, and she was not made aware of that at time of purchase. Consumer stopped driving the vehicle.