NHTSA Complaint #11624536 — 2022 CHEVROLET TAHOE

Exhaust system failure. Was told by manufacturer vehicle dealer service center that cause of the failure was not from normal use or misuse but due to manufacturing and weak metal/poor materials. No warning lights or messages ever appeared on vehicle information system. First report of exhaust smell in vehicle cabin on 4/9/24 at 38,874 miles. Vehicle dealer service center tested for leaks and found no leak. Second report of exhaust smell in vehicle cabin on 8/6/24 at 48,106 miles. Vehicle dealer service center tested for leaks and found no leak. Third report on exhaust smell in cabin on 10/31/24 to service manager who confirmed he could smell the exhaust in vehicle cabin. Car went to shop on 11/5/24 at 55,077 miles. Two exhaust leaks detected. From dealer: "Smoke tested exhaust system and checked for leaks, found a hole in the exhuast pipe right before the muffler and is likely the source of the smell." Additionally from dealer, after first repair: "After exhaust repair the vehicle was started and heard and audible exhaust leak on the drivers side. After further inspection found the drivers side exhaust manifold is leaking as well." I have been driving this vehicle for at least seven months with exhaust leaks and with exhaust coming into the cabin of my vehicle exposing myself and passengers to carbon monoxide. Reported twice to dealer and they reported no issues.