Five problems related to manifold/header/muffler/tail pipe have been reported for the 2004 Chevrolet Tahoe. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Chevrolet Tahoe based on all problems reported for the 2004 Tahoe.
My2004 chevy Tahoe lt was moving when the rear view mirror fell off the windshield. Also the exhaust manifold bolts have broken off which cause bad gas mileage and slow take offs.
The exhaust manifold bolts that thread into the cylinder heads holding the cast iron exhaust manifolds in place onto the heads break off under normal road conditions. The bolts break off and were causing an exhaust leak. My vehicle's exhaust was coming inside the vehicle making occupants ill. The steel manifold bolts are undersized for the application, and being used on iron manifolds mating to aluminum cylinder heads. I have to pay the $1000+ repair cost to fix an apparent manufacturing failure that should be recalled. No only do the broken bolts cause exhaust leaks and noise, but puts the vehicle in this condition as a possible fire risk.
Exhaust manifold bolts broken off at rear of engine on both sides.
Engine started with a ticking noise when cold. Would go away after engine warmed up. Upon inspection found 2 exhaust manifold bolts sheared on #7 cylinder, 1 broken on #8. Ticking coming from exhaust leak on #7. Upon research found that this is a common issue with these engines. Why is there no recall or safety notice as it presents a real hazard for fire and exhaust fumes entering passenger compartment.
Purchased new 2004 z-71 Tahoe 06-30-04. Noticed vehicle had a loud popping sound comming from exhaust. Dealer had a bulletin stating gm acknowledged problem but had no fix. Contacted gm six weeks ago and was told the problem would be resolved by the middle of October. Have not yet been contacted. . . .