Manifold/header/muffler/tail Pipe Problems of GMC Sierra

GMC Sierra owners have reported 13 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 2002 GMC Sierra

Failure Date: 05/27/2015

The passenger side rear exhaust manifold bolt broke off. This is a manufacturer defect. This is a very common problem with these trucks.

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2 Manifold/header/muffler/tail Pipe problem of the 2004 GMC Sierra

Failure Date: 09/09/2014

Exhaust manifold bolts breaking off causing exhaust leak where manifold bolts onto head. Due to exhaust leak now vehicle is throwing codes for catalytic threshold low. Which leads to a magnitude of problems to lack of power, poor fuel mileage and not being able to pass emission test in some states. Problem results in upward of thousand dollars in repair for faulty bolts, after researching said problem it is a common problem with gm v8 of this year older and newer as well. This is a major defect and flaw in gm's design and needs to be addressed aspa!!! this is a prob that is affecting epa laws and needs action taken against gm to fix this problem before it gets worse. Gm needs to be held responsible for their vehicles and poor design and or products that go into them that causes laws or safety to be broken or effected!.

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3 Manifold/header/muffler/tail Pipe problem of the 2004 GMC Sierra

Failure Date: 03/03/2014

I smelled exhaust fumes in the cab of the pickup truck and heard a shrieking sound under the hood. I had to put the window down to relieve my disiness from the fumes. Upon investigation I found 3 of the 6 bolts broken that fasten the exhaust manifold to the engine. Exhaust fumes are leaking from the burned out gasket.

4 Manifold/header/muffler/tail Pipe problem of the 2005 GMC Sierra

Failure Date: 07/02/2012

Exhaust in passenger compartment. Service man informed me of broken bolts and that I must replace both manifolds before next inspection.

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5 Manifold/header/muffler/tail Pipe problem of the 2001 GMC Sierra

Failure Date: 10/13/2011

Exhaust manifold bolts broke on driver side, back two. These bolts are far too small for the job and this exposes heat and exhaust gases to the environment. Creating a fire danger too.

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6 Manifold/header/muffler/tail Pipe problem of the 2000 GMC Sierra

Failure Date: 02/09/2010

Exhaust manifold bolts front and back on both sides broke off , this is common problem on this truck.

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7 Manifold/header/muffler/tail Pipe problem of the 2004 GMC Sierra

Failure Date: 01/06/2010

Multiple exhaust manifold bolts are broken on each side.

8 Manifold/header/muffler/tail Pipe problem of the 1997 GMC Sierra

Failure Date: 08/01/2005

: the contact stated in August of 2005 while the vehicle was traveling at 45 mph the muffler fell out of the exhaust. The vehicle was taken into a independent repair shop where a dual muffler was installed. The muffler was not a orginal part on the vehicle; it was installed by an indepentent repair shop.

See all problems of the 1997 GMC Sierra 🔎.

9 Manifold/header/muffler/tail Pipe problem of the 2001 GMC Sierra

Failure Date: 06/15/2005

Disc rotor delamination, anti-lock control. I was pulling a 3/4 ton van stuck in his yard, as I got him close to the hard surface ( driveway) I put on the brakes and the truck wouldn't stop, it hit the corner of his block house. No damage to the house however I had to replace all but hood and one headlight assy. 10 mph and neither bag deployed. I thought it was my own stupidity until reading all the issues on here w/ gm's braking problems. I feel a bit better about myself. The big issue !! all four rotors delaminated w/ 46,000 miles this is the 1st new truck I've owned and believe me it's been babied for sure. I was told by my service dealer there was nothing gm would do about this problem it was my problem for not driving it as much as I should (b. S. ) dealer wanted to charge me a grand to replace all the rotors and pads I did it for 500. 00 and still have the old parts. I'm sure gm should issue a recall on this, it is a definite safety issue did I fail to mention the muffler had a rattle in it and was replaced within the 1st 1000 miles, the thump in the steering column that has no way to be lubricated. Man I am disappointed in gm products.

10 Manifold/header/muffler/tail Pipe problem of the 1999 GMC Sierra

Failure Date: 02/02/2004

Two broken manifold bolts in rear drivers side of engine on 5. 3 vortec engine, exhaust leak from where manifold has separated form head. Carbon buildup and discoloration visible. High temp exhaust being released under the hood. Appears to be a very common complaint on many gm vehicles and model years.

See all problems of the 1999 GMC Sierra 🔎.

11 Manifold/header/muffler/tail Pipe problem of the 1999 GMC Sierra

Failure Date: 11/07/2003

Faulty braking system engine noise muffler replace instrument panel fault tire wear transmission automatic shifting rearend noise.

12 Manifold/header/muffler/tail Pipe problem of the 1999 GMC Sierra

Failure Date: 01/10/2003

Fuel pump will over heat and than short out. Exhaust always rattles engine knocks cat. Converters went out digital display stopped working.

13 Manifold/header/muffler/tail Pipe problem of the 2002 GMC Sierra

The vehicles muffler was covered with metal that impacted the drive shaft and caused it to wear when the vehicle went over bumps.


Other Common Engine And Engine Cooling related problems of GMC Sierra


Fuel Economy of Sierra Vehicles
Sierra Service Bulletins
Sierra Safety Recalls
Sierra Defect Investigations