How Long Does Exhaust Work Take?

Most common exhaust jobs take about 30 minutes to 3 hours, while larger repairs like manifolds or full system replacements can run 4–8+ hours; add time for rust, seized hardware, complex packaging (AWD/turbo), and parts availability. The exact timeline depends on what section is being serviced, the vehicle’s design, the condition of the undercarriage, and whether the parts are bolt-on or require welding.

Average Repair Times by Job

The duration varies widely by the specific component and whether the parts are direct-fit or custom. Below are typical shop labor time ranges you can expect for common exhaust services under normal conditions.

• Muffler replacement: 30–60 minutes (bolt-on); 45–90 minutes (weld-in)
• Resonator swap: 30–90 minutes (access- and rust-dependent)
• Cat-back system: 1–2.5 hours (more time for dual-exit or large SUVs/trucks)
• Axle-back system: 45–90 minutes
• Flex pipe replacement: 1–2 hours (often requires cutting/welding)
• Oxygen (O2) sensor replacement: 20–45 minutes each (add time if seized)
• Mid-pipe/catalytic converter (direct-fit): 0.7–1.5 hours
• Catalytic converter (integrated with manifold): 2–5 hours (tight access/heat shields)
• Exhaust manifold or headers: 3–8+ hours (engine bay packaging and rust are key)
• Downpipe (turbo vehicles): 1–3 hours (heat shielding and AWD subframes add time)
• Hangers/brackets/straps: 15–30 minutes each
• Custom-bent sections or full custom systems: 2–5+ hours depending on complexity
• DPF/SCR components on modern diesels (OEM-compliant service): 2–4 hours

These windows assume typical shop environments and tools. Vehicles with heavy corrosion, broken studs, or tight packaging can move times to the upper end or beyond.

Key Factors That Change the Timeline

Beyond the part itself, several real-world variables influence how long exhaust service will take. Understanding these helps set expectations before you book time at a shop.

• Rust and seized hardware: Adds time for torching, cutting, drilling, and re-tapping
• Vehicle layout: AWD, turbos, skid plates, and undertrays complicate access
• Weld-in vs. bolt-on: Cutting and fabrication extend labor versus direct-fit clamps
• Part quality and fitment: Aftermarket tolerances can require adjustments
• Additional damage: Warped flanges, broken studs, or crushed pipes expand scope
• Emissions equipment: Heat shields, sensors, and legal compliance steps add tasks
• Lifts and tools: Proper shop equipment speeds work versus driveway repairs
• Weather and road salt history: Snow-belt cars typically need more time

When these factors stack up—say, an older AWD vehicle from a rust-prone region—plan for extra labor and potential overnight stays if parts or machining are needed.

Diagnosis vs. Repair Time

Pinpointing the source of noise, leaks, or emissions faults comes first and can be quick or involved depending on the symptoms and codes.

• Basic noise/leak check: 10–30 minutes (visual inspection, smoke test)
• Check engine light (emissions-related): 0.5–1.5 hours (scan, live data, sensor testing)
• Complex drivability/efficiency issues: 1–3 hours (backpressure tests, advanced diagnostics)

If diagnostics confirm a straightforward issue—like a split flex pipe—repair can often follow immediately if parts are on hand; otherwise, scheduling and parts ordering add time.

Scheduling, Parts, and Wait Times

Even when labor is short, logistics can stretch the total time your vehicle is out of service. Here’s what typically influences the calendar.

• Shop backlog: Same-day service is common for quick jobs; complex work may book days out
• Parts availability: In-stock mufflers/sensors can be done same day; specialty manifolds or OEM catalytic converters may take 1–3 days
• Drop-off vs. while-you-wait: Expect 30–120 minutes for quick, scheduled jobs you can wait on
• Unexpected findings: Broken studs or warped flanges can push a job into the next day

Confirm parts availability and the shop’s schedule before arriving; this can be the difference between an hour’s wait and leaving the vehicle overnight.

How to Get a Realistic Estimate

Clear communication and a few quick checks can tighten your time estimate and avoid surprises.

• Share symptoms and context: Noise type, when it happens, recent repairs, and codes
• Ask for a labor-time range: Request best case and worst case including rust contingencies
• Confirm part type: Direct-fit vs. universal, and whether welding is required
• Request hardware and gasket plan: New bolts, studs, and seals save time later
• Discuss emissions compliance: Ensure parts meet local/federal regulations
• Plan for add-ons: O2 bungs, hangers, or heat shields often need replacement too

With this information, most shops can quote a realistic window and prepare parts and tools ahead of your appointment.

What’s Reasonable to Expect

Putting the pieces together, these are practical expectations for common scenarios.

• Quick muffler or axle-back on a modern, non-rusty car: In and out within 1–2 hours
• Cat-back system on an SUV or truck: About 1.5–3 hours with proper lift and tools
• Flex pipe or resonator on a higher-mileage car: 1–2.5 hours, longer if welding and rust
• Manifold/cat-integrated unit on an older AWD vehicle: Potentially a full day
• Custom fabrication or dual-exit setup: Half-day to full day depending on complexity

If you’re on a tight schedule, aim for jobs with in-stock, direct-fit parts and book the first morning slot to reduce delays.

Summary

Most exhaust repairs take 30 minutes to 3 hours, while complex work—manifolds, integrated catalytic converters, custom systems—can run 4–8+ hours. Condition (rust), vehicle design (AWD/turbo), and parts type (weld-in vs. bolt-on) are the biggest drivers of time, followed by shop scheduling and parts availability. Confirm the scope, parts, and a best/worst-case labor window with your shop for the most accurate timeline.

How to know if exhaust is working?

Increased engine noise is a common sign of an exhaust leak. Listen for a loud rumble, especially while accelerating. You may also hear intermittent popping or hissing noises while the engine is running. An exhaust leak can affect the performance of your engine.

How long does exhaust work take?

Exhaust work can take anywhere from 30 minutes to several hours, depending on the specific job. Simple muffler replacements might be done in under an hour, while replacing an entire system or working with older vehicles, high-performance cars, or heavily rusted components can extend the time significantly, sometimes requiring a whole day. Factors like the complexity of the system, the vehicle’s make and model, the extent of rust, and the availability of parts all influence the total repair time. 
Simple Exhaust Work (Muffler Replacement) 

• 30 minutes to 1 hour: For most standard vehicles, a professional can replace a muffler or the back box of the exhaust in this timeframe.

More Complex Exhaust Work (Cat-Back or Full System)

• 1 to 2 hours: Opens in new tabThis is a more typical time for a cat-back exhaust (from the catalytic converter to the rear) if everything goes smoothly. 
• Several hours: Opens in new tabReplacing a whole system or dealing with heavily rusted or complex exhaust setups can take 3.5 to 6 hours or more. 

Factors That Influence Repair Time

• Vehicle Specifics: Older vehicles or high-performance models may have more intricate systems that take longer to replace. 
• Rust and Corrosion: Rusted or seized bolts and components significantly increase the time needed for removal and replacement. 
• Part Availability: If a specific part needs to be ordered, the overall repair time will be extended. 
• Tools and Equipment: Having a portable lift can make the job easier and faster. 
• DIY vs. Professional: Professional installation includes labor charges but also offers a guarantee. A DIY project can take much longer due to inexperience, especially with complex systems or difficult components. 

How long to wait before working on exhaust?

Handling hot exhaust components can be dangerous due to their extremely high temperatures. It typically takes 30 minutes to an hour for an exhaust pipe to cool down after the engine is turned off, but this time frame can vary based on outside temperature, engine size, and the type of metal used in the exhaust system.

How much should it cost to replace an exhaust?

Exhaust replacement usually costs between £300 and £600, depending on your car, the parts, and labour. Smaller cars are cheaper, while larger or luxury models cost more. Most of the time, only sections after the catalytic converter need replacing, as these are more prone to rust.