2003 Chevrolet Tahoe Engine Problems

Your check engine light came on, and the dealer found two broken bolts on your exhaust manifold. The shop has had your vehicle for over two weeks with repair costs already exceeding $1,400, and they expect final costs to be significantly higher because they need to bring in a specialist mechanic to remove the broken bolts. Fixing this will likely involve removing the exhaust manifold and extracting the broken bolts, possibly requiring specialized tools or techniques.

I AM ONE OF MILLIONS OF 1999-2007 CHEVROLET V8 TRUCK ENGINE OWNERS, WHO IS TOLD BY THEIR GM MECHANIC THAT THE EXHAUST MANIFOLD BOLT(S) HAS BROKEN, LEADING TO EXPENSES RANGING FROM $500 TO $1,500. GM BUILT THE ENGINES WITH SUBSTANDARD BOLTS THAT DO NOT LAST IN COMPARISON TO THE REST OF THE ENGINE AND VEHICLE. ONE OR MORE WILL BREAK, WHICH CAUSES AN EXHAUST LEAK AND CHECK ENGINE LIGHT, AND THEREFORE THE VEHICLE IS OUT OF SERVICE AS IT CANNOT PASS STATE EMISSIONS TESTS. ADDITIONALLY, SOME OF THE EXHAUST LEAKS ARE NEAR OTHER SENSORS WHICH CAN CAUSE FAULTY READINGS OR UNSAFE CONDITIONS. THOSE WHO ATTEMPT TO SELF-FIX THIS GM-CAUSED PROBLEM FACE UNSAFE CONDITIONS, AS THEY ARE DIFFICULT TO GET TO, REQUIRE A WELDER TO FIX, MAY DAMAGE SURROUNDING EQUIPMENT, ETC. THE NEED FOR A RECALL IS WELL-KNOWN AND VERY LARGE, AND IT IS TIME FOR A RECALL ON THESE, SIMILAR AS HAVE FORD AND TOYOTA HAD RECALLS ON SIMILAR ISSUES. GM SURVIVED DUE TO A BAILOUT FROM TAXPAYERS (MANY OF THEM THEIR OWN CUSTOMERS); IT IS TIME FOR GM TO PERFORM RESPONSIBLY TO A NEEDED RECALL. IN THE PICTURE, THE BROKEN-OFF BOLT HEAD IS EVIDENCED A FEW INCHES TO THE LEFT OF THE RUSTY ONE THAT STILL EXISTS, WHERE THERE IS AN EMPTY HOLE (THE BOLT REMAINS STUCK INSIDE THE ENGINE, AND REQUIRES BORING OUT OR WELDING SOMETHING ON IN ORDER TO BACK IT OUT).

ON NOVEMBER 5, 2015, I TOOK MY 2003 TAHOE IN DUE TO THE FACT THAT AN EXHAUST MANIFOLD BOLT HAD SHEARED OFF DURING THE NORMAL COURSE OF DRIVING. I BOUGHT MY TAHOE NEW AND HAVE ALWAYS HAD IT SERVICE AT THE MCCARTHY-MORRIS CHEVROLET DEALERSHIP ON OVERLAND PARK, KS. I REALIZE THAT OVER TIME PARTS ON A VEHICLE WILL BREAK AND AT 118,000 MILES I SHOULD EXPECT TO INCUR MAINTENANCE EXPENSES. HOWEVER, BASED ON MY RESEARCH GM USED A SUBSTANDARD BOLT AND THIS ISSUE IMPACTS MILLIONS OF GM V8 MOTORS. FROM A SAFETY PERSPECTIVE, I HAD THE REPAIR DONE BECAUSE I DIDN'T WANT TO RISK HAVING EXHAUST FUMES ENTERING THE CAB OF MY VEHICLE. MY UNDERSTANDING IS THAT THIS TYPE OF EXHAUST LEAK COULD HAVE EPA IMPLICATIONS AS WELL. IN ORDER TO HAVE THE REPAIR DONE, THE DEALERSHIP HAD TO PULL THE HEAD BECAUSE ONE OF THE TWO BOLTS THAT SHEARED OFF WAS FLUSH WITH THE HEAD AND HAD TO BE DRILLED OUT. TOTAL COST WAS $1,381.07. THE SAD FACT IS THAT AFTER GETTING THE VEHICLE BACK, IT IS RUNNING ROUGH AND CHANCE ARE I WILL HAVE TO RETURN IT BACK TO THE DEALERSHIP FOR ADDITIONAL REPAIRS. I CONTEND THAT WHEN MAJOR REPAIRS LIKE THIS ARE DONE, THE VEHICLE IS SELDOM THE SAME. IT TOOK 5 DAYS TO GET IT BACK DO TO THE WEEKEND. IF THE NHTSA WON'T TAKE ANY ACTIONS OVER CONCERNS ABOUT THE EXHAUST LEAK, I HOPE SOME LAW FIRM MIGHT CONSIDER STARTING A CLASS ACTION SUIT. I HAVE NO ISSUE PAYING FOR REPAIRS CAUSED BY NORMAL WEAR AND TEAR, BUT THIS APPEARS TO BE A DEFECT THAT RESULTED FROM CHEVROLET USING A SUBSTANDARD BOLT.

TL* THE CONTACT OWNS A 2003 CHEVROLET TAHOE. WHILE DRIVING AT 45 MPH, THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE IDLE CONTROL NEEDED TO BE RESET. THE VEHICLE WAS NOT REPAIRED. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 208,000.

TL* THE CONTACT OWNS A 2003 CHEVROLET TAHOE. WHILE DRIVING APPROXIMATELY 55 MPH, THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO RESTART, BUT THE FAILURE RECURRED ON MULTIPLE OCCASIONS. THE DEALER STATED THAT THE THROTTLE BODY SWITCH NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED AND THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 104,000.

I TOOK MY 2003 CHEVY TAHOE INTO THE DEALERSHIP BECAUSE OF PERFORMANCE AND GAS ISSUES AND WAS TOLD I HAD 2 BROKEN EXHAUST MANIFOLD BOLTS. THE REPAIR WAS ESTIMATED TO OVER $1000. I KNOW THAT THIS IS A MAJOR ISSUE WITH GMC AND CHEVY ENGINES WITH MANY COMPLAINTS. THE MANUFACTURER SHOULD STAND BY THEIR PRODUCT AND FIX THIS ISSUE INSTEAD OF MAKING THEIR CUSTOMERS PAY FOR A DEFECT THAT EXISTS WITH THEIR PRODUCT. I WAS TOLD THAT MY VEHICLE WOULD NOT PASS SAFETY INSPECTION WITHOUT THIS FIX. *TR

TL* THE CONTACT OWNS A 2003 CHEVROLET TAHOE. THE CONTACT STATED THAT HE CONTINUOUSLY HEARD A TICKING NOISE WHENEVER THE VEHICLE WAS STARTED. THE VEHICLE WAS TAKEN TO A DEALER WHO DIAGNOSE THAT THE EXHAUST MANIFOLD BOLTS BROKE OFF. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 196,000. UPDATED 10/15/12 *CN UPDATED 10/23/2012 *JS

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. *TR

AIR CONDITIONER, COMPRESSOR, CLUTCH AND BELT TENSIONOR ON CHEVROLET TAHOE. BELT TENSIONOR BREAKS LOCKING UP CAUSING COMPRESSOR CLUTCH TO SIEZE THEN CAUSING COMPRESSOR TO DISENTERGRATE INTERNALLY SHOOTING INTERNAL COMPONENTS THRU ACCUMALATOR AND INSIDE VEHICLE CLIMATE CONTROL SYSTEM. SERPENTINE BELT TENSTSIONOR COULD CAUSE BELT TO BREAK WHICH DRIVES THE ENTIRE SYSTEM TO INCLUDE POWER STEERING. THIS IS A COMMON PROBLEM FOR CHEVROLET MODELS, HOWEVER IT MAY ONLY BEGIN HAVING THE PROBLEM AT 3-4 YEARS OF OWNERSHIP THEREFORE APPEARING TO BE A NORMAL BREAKDOWN OF COMPONENTS. THE PROBLEM IS COMMON ENOUGH THE DEALERS AND EXPERIENCED MECHANICS MAINTAIN THE PARTS AS BASIC STOCKED ITEMS. *TR

THE REDUCED ENGINE POWER LIGHT CAME ON AND REDUCED THE CAR'S POWER TO ONLY BE ABLE TO GO 20 MPH. I DID REACH 30 MPH WITH A DOWN-SLOPE. I WAS VERY SCARED AND HAD MY TWO CHILDREN IN THE CAR. THANKFULLY, I WAS ABLE TO SAFELY PULL OVER TO THE SIDE OF THE ROAD. UPON RESEARCHING THIS ISSUE WITH MY CAR MAKE AND MODEL, IT SEEMS TO BE A COMMON PROBLEM AND A VERY SERIOUS ISSUE. THE ENGINE'S POWER JUST PULLED BACK WITHOUT WARNING! I AM TAKING THE CAR TO BE SERVICED TOMORROW BUT CANNOT FATHOM TO THINK WHAT COULD HAVE HAPPENED!

LTR ON BEHALF OF, WHO SUFFERED BURNS WHEN THEIR 2003 CHEVROLET TAHOE CAUGHT FIRE WHILE DRIVING; THEY DID NOT REC'D RESPONSE TO 3/23/10 LTR FWD TO NHTSA; REPLY ATTN KEITH NELSON/ROSEVILLE OFC; ES HAVE NO REC OF PREV CORRESPOND *TGW THE FAN MOTOR DID NOT SHUT OFF EVEN THOUGH THE ENGINE WAS TURNED OFF AND THE KEY WERE NOT IN THE IGNITION. *JB

2003 CHEVROLET TAHOE CAUGHT ON FIRE *GR THE CONSUMER STATED THE FAN MOTOR WOULD NOT SHUT OFF. THE CONSUMER STATED HER FATHER RECEIVED 2ND DEGREE BURNS ON HIS WHEN TRIED TO PUT THE FIRE OUT. *JB

GM MODELS 2003-2007 LIGHT PICK-UPS AND SPORT UTILITY. CONSUMER STATES DEFECTIVE DASH CLUSTERS. *TGW THE CONSUMER OWNS A 2003 CHEVROLET TAHOE. SHE STATED SHE EXPERIENCED A PROBLEM WITH THE INSTRUMENT CLUSTER READING 70 MPH ALSO, THE WATER PUMP FAILED. *JB

BOUGHT VEHICLE IN FEBRUARY OF 2009 USED AFTER DRIVING TRUCK FOR ABOUT 10 DAYS WE REALIZED THAT THE SPEEDOMETER WAS NOT MOVING WHEN THE VEHICLE WAS IN MOTION. THEN AFTER THAT THE SPEEDOMETER WOULD MOVE UP IN SPEED AFTER DRIVING THE CAR FOR ABOUT 20 MINUTES BUT THEN STAY AT THE 30MPH WHEN STOPPED ONCE THE CAR WOULD BEGIN MOVING AGAIN THE SPEED WOULD CONTINUE TO GO UP FROM THE 30MPH MARK RESULTING IN THE SPEEDOMETER READING 60MPH WHEN THE VEHICLE WAS ACTUALLY ONLY GOING 30MPH. THIS HAS CONTINUED EVERY DAY SINCE IT WAS NOTICED SO WHEN DRIVING THE CAR YOU NEVER KNOW HOW FAST THE CAR IS ACTUALLY TRAVELING. *TR

A SCHEDULED OIL CHANGE ON MY 2003 CHEVY TAHOE REVEALED BROKEN METAL PIECES. CORMIER CHEVROLET WHO IS MY SERVICE/PURCHASE DEALER DETERMINED THAT THE DEBRIS CAME FROM 3 BROKEN ROCKER ARMS. CORMIER MADE THE NECESSARY REPAIRS UNDER WARRANTY, HOWEVER, 3 MONTHS LATER THE SAME PROBLEM MANIFESTED ITSELF AGAIN. THIS TIME CORMIER REPLACED ALL 16 ROCKER ARMS, BUT I HAD TO PAY A $100.00 DEDUCTIBLE. *TR I FEEL THE NECESSARY REPAIRS WERE CAUSED BY DEFECTIVE ASSEMBLY AND/OR PARTS. ESPECIALLY WHEN MY VEHICLE IS DRIVEN 98% OF THE TIME ON LOCAL ROADS ONLY, AND HAS JUST 35,015 TOTAL MILES AND WAS PURCHASED BRAND NEW.

WHEN STARTING THE VEHICLE, CHECK ENGINE LIGHT COMES ON AND DASH SAYS REDUCED ENGINE POWER. VEHICLE WILL ONLY DRIVE ABOUT 15 MILES PER HOUR. UPON RESEARCHING THIS THROUGH VARIOUS INTERNET WEBSITES, THIS SAME PROBLEM HAS AND IS HAPPENING TO A HUGE AMOUNT OF 2003 TAHOE OWNER'S AND IT'S ALWAYS A FAULTY WIRING HARNESS PROBLEM - YET GM REFUSES TO ACKNOWLEDGE THERE IS A PROBLEM. ON A SIDE NOTE, HEADLIGHTS HAVE ALWAYS BEEN VERY DIM. *TR

MY FIANCE AND I BOUGHT A 2003 CHEVY IMPALA IN NOV OF 2006 WITH ONLY 40,000 MILES. IN JULY OF 2007, THE CAR WAS STARTED AND SHUT OFF BY ITSELF A FEW MINUTES LATER. IT WOULD THEN NOT START. WE FIRST HAD IT TOWED TO A LOCAL SHOP THAT INFORMED US THAT THE UPPER INTAKE MANIFOLD HAD CRACKED. IT LEAKED ANTIFREEZE INTO THE CYLINDERS, THE SPARK PLUGS AND OTHER PARTS OF THE ENGINE AND THE COST FOR REPAIR WOULD BE 1400.00. WE HAD THE CAR TOWED TO A 2ND SHOP FOR A 2ND OPINION. THEY TOLD US THAT THE ANTIFREEZE THAT LEAKED HAD TOTALLY LOCKED UP THE ENGINE AND WE NEEDED A WHOLE NEW ONE. THAT WAS GOING TO COST US AT LEAST 2,000 FOR A USED ONE. WE THAN DECIDED THAT A 4 YEAR OLD CAR WITH 60K MILES ON IT SHOULD NOT BE IN NEED OF A NEW ENGINE SO WE AGAIN HAD IT TOWED TO A CHEVROLET DEALER REPAIR SHOP. THEY TOLD US THE SAME THING. THE CAR WAS OFFICIALLY IN NEED OF A WHOLE NEW ENGINE. WE CONTACTED CHEVROLET'S CUSTOMER CARE DEPT AND THEY ARE SO FAR UNWILLING TO HELP. WE'VE ONLY HAD THE CAR 8-9 MONTHS AND ARE CONTINUING TO MAKE PAYMENTS ON THE LOAN. PER THE DEALER, THE USED ENGINE WILL COST US 3000.00 AND A NEW ONE WILL COST IS 5050.00. *JB

EVER SINCE PURCHASING MY CHEVROLET TAHOE LT BRAND-NEW IN AUGUST OF 2003, THE MUFFLER AND/OR THE EXHAUST SYSTEM HAS MADE AN EXPLODING SOUND BOTH WHILE THE VEHICLE IS RUNNING AND AFTER IT IS SHUT OFF. AT STOPLIGHTS AND AFTER BEING PARKED, YOU BOTH HEAR AND FEEL EXPLOSIONS FROM UNDER THE TRUCK. GM CONTENDS THE SOUND IS STEAM BUILDING UP IN THE MUFFLER AND EXPLODING, BUT ADMITS IT IS NOT A "NORMAL" BACKFIRE, AND STATES THAT SOME TAHOES DO IT, AND SOME DO NOT. THEY HAVE RELEASED TWO SEPARATE FIXES FOR THE PROBLEM BUT NEITHER HAS BEEN EFFECTIVE, AND THE LAST ONE CAME OUT OVER A YEAR AGO. OFFICIAL GM POLICY PROHIBITS REPLACING ANY MUFFLERS/EXHAUST SYSTEMS ON VEHICLES EXHIBITING THIS PROBLEM - OWNERS ARE SIMPLY TOLD THE EXPLOSIONS ARE NORMAL. AFTER MUCH DISCUSSION, GM REPLACED MY MUFFLER, AND THE SECOND ONE DOES THE SAME THING. NEEDLESS TO SAY, IT IS AN ALARMING SOUND AND FEELING TO HAVE IN A NEW VEHICLE, AND LOGIC DICTATES THAT STEAM EXPLOSIONS INSIDE A METAL BOX CAN ONLY GO ON FOR SO LONG BEFORE SERIOUS DAMAGE IS DONE (I.E. THE MUFFLER ITSELF EXPLODES NEAR THE GAS TANK.) I'M NOT SURE WHAT THE NHTSA CAN DO, BUT ANY HELP YOU CAN PROVIDE IS MOST WELCOME.*AK

WHILE DRIVING VEHICLE LOST POWER. VEHICLE WOULD NOT ACCELERATE OVER 10 MPH. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. *AK

THE MUFFLER ON MY 2003 CHEVROLET SILVERADO NEEDS ITS SECOND MUFFLER IN AS MANY YEARS. IT APPEARS THE BAFFLE IS BECOMING LOOSE DUE TO INSUFFICIENT WELDS WITHIN THE MUFFLER. THIS IS CAUSING A VIBRATION A VARIOUS RPM/SPEEDS.*AK

ENGINE KNOCKS WHEN IT STARTED AFTER SITTING FOR A WHILE UNTILL OIL PUMP PICKS UP.I PERSONALLY KNOW OF FIVE OTHER 5.3 LITER V8S THAT HAVE THE SAME PROBLEM,BUT MY DEALERSHIP HAS NEVER HEARD OF THIS .I FIND THIS HARD TO BELIEVE. A FRIEND TOLD ME THAT THERE WAS A TSB REGUARDING A CHECK VALVE OF SOME KIND THAT WOULD STOP THIS. *AK

"REDUCED ENGINE POWER" MESSAGE DISPLAYED 3 TIMES WITHIN 4100 MILES OF BRAND NEW TAHOE. ON 4TH VISIT, DEALER REPLACED THROTTLE BODY WITH A NEW ONE AT 4366 MILES. *JB

CONSUMER STATED VEHICLE RUMBLED AND MADE NOISE WHILE STOPPING AT A RED LIGHT OR STOP SIGN. CONSUMER TOOK VEHICLE TO DEALER/MECHANIC 5 TIMES, THEY REPLACED THE MUFFLER, BUT THE PROBLEM WAS GETTING WORSE. *AK

VEHICLE EXPERIENCED A TOTAL IMMEDIATE LOSS OF POWER WHILE DRIVING.*MR ALMOST REAR ENDED ANOTHER VEHICLE AT A HIGH SPEED TWICE DURING THE LAST BREAK DOWN ON A BUSY HIGHWAY. THE CONSUMER WAS VERY DISSATISFIED WITH THE DEALERSHIP HELP IN ASSISTING WITH VEHICLE. PLEASE INVESTIGATE *CB

WE HAVE A 2003 TAHOE WITH A 5.3L V8. THERE IS A HISSING NOISE AND A VIBRATING IN THE ENGINE AFTER RUNNING FOR ABOUT 15 MINUTES. THE DEALERSHIP CAN'T FIX IT AND DOESN'T KNOW WHAT IS WRONG WITH IT. THEY THINK IT HAS TO DO WITH THE A/C BUT THEY REPLACED COMPRESSOR AND BELT AND IT STILL MAKES THE NOISE.*AK

THE VEHICLE VIBRATED, WHICH WAS DUE TO A LOOSE EXHAUST SYSTEM.*JB