Manifold/header/muffler/tail Pipe Problems of GMC Sierra 2500

GMC Sierra 2500 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. Also please check out the statistics and reliability analysis of GMC Sierra 2500 based on all problems reported for the Sierra 2500.

1 Manifold/header/muffler/tail Pipe problem of the 2004 GMC Sierra 2500

Failure Date: 11/27/2018

Tl the contact owns a 2004 GMC Sierra 2500. While driving approximately 45 mph, the contact noticed a lot of white smoke emerging from the tail pipe. The vehicle was previously repaired under warranty by gwatney Buick GMC (5700 landers rd, north little rock, ar 72117) for the same failure as listed in an unknown technical service bulletin regarding the fuel injectors. The vehicle was not diagnosed or repaired for the recent failure. The manufacturer was notified of the failure. The approximate failure mileage was 90,000.

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2 Manifold/header/muffler/tail Pipe problem of the 2004 GMC Sierra 2500

Failure Date: 08/28/2018

Exhaust manifold bolts broken.

3 Manifold/header/muffler/tail Pipe problem of the 2009 GMC Sierra 2500

Failure Date: 02/16/2018

My pickup has broken exhaust manifold bolts, causing the check engine light to come on, the code is for an emission problem, g. M. Will not repair it under the emission warranty, at this time there are 40,021 miles on the vehicle.

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4 Manifold/header/muffler/tail Pipe problem of the 2010 GMC Sierra 2500

Failure Date: 04/10/2014

Exhaust manifold bolt, driver side, aginst fire wall, broke off under normal driving. It is my understanding that there has been a big problem with this. GMC should be made to repair this at their cost, the est. Repair cost from a dealer is $1,400 - $1,700. This is a bunch of bs. Is gm covering up this screw up too????.

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5 Manifold/header/muffler/tail Pipe problem of the 2001 GMC Sierra 2500

Failure Date: 01/01/2014

Exhaust manifold leak due to broken exhaust manifold bolt. I am the original owner of the vehicle. The vehicle has been regularly and properly maintained. I understand this is a common problem for this gm vehicle due to defective parts. I purchased this vehicle new from a local GMC dealer.

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6 Manifold/header/muffler/tail Pipe problem of the 2008 GMC Sierra 2500

Failure Date: 09/06/2013

When traveling merging on I-70 outside of london ohio my truck started making very loud exhaust sound. After inspection found that driver side and passenger side rear exhaust manifold bolts where broke off allowing unfiltered exhaust to pass. If leak would have been too bad the high temperature of the exhaust could potentially cause a fire inside the engine compartment. The exhaust also broke welds off the exhaust causing the exhaust to fall the break is where the h-pipe come together.

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7 Manifold/header/muffler/tail Pipe problem of the 2005 GMC Sierra 2500

Failure Date: 08/20/2013

2005 GMC 2500hd with 6. 0 liter gas motor. Left and right bank exhast manifold to engine bolts broken off in head. Leaking exhast fumes and causing my check engine light to come on. Gm need to have a recall on this due to the number of vehicles out there with this problem. This is also an emission problem due to it will cause the cat convertor to overheat. . Epa? thank you.

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8 Manifold/header/muffler/tail Pipe problem of the 2005 GMC Sierra 2500

Failure Date: 11/13/2012

All exhaust manifold bolts are defective causing them to break, when they do the exhaust manifold separates from the cylinder head in turn directing all emissions from the engine into the air, and cabin of the vehicle. This could cause a fire if not corrected. One spark would set the vehicle on fire.

9 Manifold/header/muffler/tail Pipe problem of the 2002 GMC Sierra 2500

Failure Date: 06/07/2012

Three broken manifold bolts. From what I hear this is a common occurrence. The broken one close to firewall, will have to pull engine to fix. There should be a recall on these manifold bolts.

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10 Manifold/header/muffler/tail Pipe problem of the 2004 GMC Sierra 2500

Failure Date: 06/01/2012

The contact owns a 2004 GMC Sierra 2500 hd. The contact stated that while driving various speeds he would hear a loud noise coming from the engine. The vehicle was taken to an independent mechanic for diagnosis where the contact was advised that the manifold bolts were fractured and needed to be replaced. The vehicle was not repaired. In addition, the contact also noticed that the instrument cluster failed and he was unable to determine what speed he was traveling, how much fuel was in the vehicle, etc. The vehicle was taken for inspection where the contact was advised that the cluster wiring failed and needed to be replaced. The manufacturer was contacted however, they offered no assistance. The failure mileage was approximately 50,000. The current mileage was approximately 53,000.

11 Manifold/header/muffler/tail Pipe problem of the 2005 GMC Sierra 2500

Failure Date: 11/16/2011

Broken exhaust manifold bolts. Front and rear manifold bolts have broken on both the passenger and driver sides. As a result exhaust manifolds are now warping putting undue stress on remaining manifold bolts and creating an exhaust leak. Bolts are steel, manifolds are cast, and heads are aluminum. Dissimilar metals, heat, and moisture have caused the bolts to prematurely rust and fail. Emissions dilution will not allow for a passing smog test in 2013. GMC refuses to address the issue at hand, even though this is a recurring issue on all v8 engines. Estimate to repair; $2500.

12 Manifold/header/muffler/tail Pipe problem of the 2004 GMC Sierra 2500

Failure Date: 07/22/2011

I bought this truck from dealer with 40151 miles. I have this truck from 2007 to present time with the mileage at 51,000 miles. The truck has been used for personal use only. I feel that there should be a investigation into this problem because this will effect millions of gm trucks. This problem will cost over $1000. To fix because of possible fire,engine failure, emissions problems, other very costly problems that will relate to the bolts breaking off from defect on the exhaust manifold. This can cause very serious problems. (this is as serious as the Toyota car problems or worse). I also think with the new air emissions standards these trucks will not pass the inspections. Because of the exhaust leaks on the motor. There is no doubt I feel this should & can be a class action suit. Gm knows of this defect of the bolt but still no recall. Why must it take someone to get killed or hurt before they fix the problem. I don't have thousands to fix this problem & now when I drive I am worried about the truck going on fire. Gm must do the right thing to correct the problem the caused. Please keep me informed. Thank [xxx] information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

13 Manifold/header/muffler/tail Pipe problem of the 2004 GMC Sierra 2500

Failure Date: 02/19/2010

Vehicle has experienced multiple instances of exhaust manifold bolt failures at the cylinder head on both banks of the engine.

14 Manifold/header/muffler/tail Pipe problem of the 2004 GMC Sierra 2500

Failure Date: 06/06/2007

My vehicle had brake lines replace two times with less than 65,000 miles because breaks stop working. Fuel line replaced under 55,000 miles because it made check engine light come on speedometer erratic,oil pressure gauge high and low,fuel gauge erratic under 65,000 miles. Loud noise from engine service technician reported the exhaust manifold bolts has broken to call a white smoke from the motor. Everything happened with consider to be low mileage in talking to gm they don't care because enough report has not been made.

15 Manifold/header/muffler/tail Pipe problem of the 2000 GMC Sierra 2500

Failure Date: 06/16/2005

Right rear manifold bolt broke allowing exhaust leak with accompanying noise. Repairs were made with subsequent failure. Dealers declined any type of warranty or other assistance. Subject bolt has failed for third time.

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Other Common Engine And Engine Cooling related problems of GMC Sierra 2500


Safety Ratings of Sierra 2500 Cars
Sierra 2500 Service Bulletins
Sierra 2500 Safety Recalls
Sierra 2500 Defect Investigations