How Much Do Headers Cost for a Truck?

Truck exhaust headers typically cost $200–$2,000 for parts as of 2025, with most daily-driver “shorty” headers running $300–$800 and long-tube headers $700–$1,800; professional installation usually adds $300–$1,200 or more depending on labor time, rust, and drivetrain complexity. All-in, expect $600–$3,200+ for gas half-ton trucks, with premium stainless or catted long-tube systems installed often landing between $1,800 and $3,200+.

What You’re Paying For

The price of truck headers is driven by the type of header you choose, the materials and coatings, emissions compliance, and how difficult your particular truck is to work on. Labor can vary widely by region and by whether the truck is 2WD or 4WD, and whether there’s rust or broken manifold bolts to solve.

Parts: Types and Typical Price Ranges (2025)

The list below outlines common header types for gas trucks and what you can expect to pay for each category, before tax and shipping.

• Shorty headers (direct-replacement style): $300–$800 in mild steel or 409 stainless; 304 stainless and premium brands run $600–$1,100.
• Mid-length headers: $500–$1,000 depending on brand, material, and coating.
• Long-tube headers (off-road/track or performance street): $700–$1,800 for uncatted systems in stainless; top-tier brands can exceed $2,000.
• Complete long-tube systems with high-flow catalytic converters/Y-pipe: $1,200–$2,500+, depending on cat quality and 49-state vs CARB-legal versions.
• Material and coating premiums: 304 stainless typically adds $150–$500; ceramic coatings add $150–$400; heat shields/wraps another $25–$200.
• CARB-legal (California emissions) versions: usually add $50–$250 and can limit the model-year range available.

These prices reflect major brands commonly used on half-ton gas trucks; niche or race-only offerings can be higher, while budget steel options can be cheaper but may have shorter lifespans in harsh climates.

Labor: Installation Time and Cost

Labor depends on engine bay access, 2WD vs 4WD, rust, and whether the shop must extract broken bolts or modify exhaust connections. Here’s how that typically translates into time and money.

• Book time: 3–6 hours for shorty headers on a clean, 2WD half-ton; 5–10 hours for long-tubes, 4WD trucks, or rust-belt vehicles.
• Shop rates (U.S., 2025): $90–$175/hour independent shops; $150–$250/hour at dealerships and specialty performance shops.
• Typical labor totals: $300–$900 for shorties on easy applications; $700–$1,500+ for long-tubes or rusty trucks.
• Added time: Extraction of seized/broken manifold studs can add $100–$400+; custom welding or Y-pipe fitment adds more.

Because labor can swing widely, many shops won’t give a firm quote until they see the truck and understand whether hardware is seized or if additional exhaust parts are needed.

Real-World Price Examples by Popular Truck

Below are ballpark parts-and-labor ranges for common gas trucks, assuming name-brand parts and typical labor conditions. Local pricing and availability will vary.

• Ford F-150 5.0L (2011–2024): Shorty headers $350–$800; long-tubes $900–$1,600. Install 5–8 hours: $500–$1,200. Typical total: $1,100–$2,800.
• Chevy Silverado/GMC Sierra 1500 5.3L/6.2L (2014–2024): Shorties $300–$700; long-tubes $800–$1,500. Install 4–8 hours: $450–$1,200. Typical total: $900–$2,700.
• Ram 1500 5.7L Hemi (2009–2024): Shorties $400–$900; long-tubes $1,000–$1,800. Install 5–9 hours: $600–$1,300. Typical total: $1,200–$3,000.
• Toyota Tundra 5.7L (2007–2021): Long-tubes $900–$1,600; CARB-legal options vary by year. Install 6–10 hours: $700–$1,500. Typical total: $1,800–$3,100.
• Toyota Tacoma 3.5L (2016–2023): Headers $600–$1,100 depending on CARB status. Install 5–9 hours: $600–$1,300. Typical total: $1,200–$2,300.
• Older rust-prone trucks (various): Add $150–$500 for hardware extraction and potential manifold surface cleanup.

These examples reflect mainstream brands in 304/409 stainless with optional coatings; premium catted systems or high-end brands can push totals higher.

Extra Costs You Might Encounter

Beyond the headers themselves, many installs require additional parts or services. Plan for the following potential add-ons.

• Gaskets and hardware: $20–$60 for quality multi-layer steel gaskets; $15–$50 for new studs/nuts.
• Oxygen sensor extensions/relocators: $20–$80; new O2 sensors if old units are seized: $40–$120 each.
• Tuning: Often recommended for long-tubes; handheld tuner or dyno session: $300–$700.
• Y-pipe/mid-pipe modifications: $150–$500; more if custom welding is needed.
• Heat management: Wraps or shields $25–$200 to protect nearby components and reduce cabin heat.
• Catalytic converters: If your kit requires new cats to remain emissions-legal, budget $300–$1,200 each.
• Shipping and taxes: $25–$150+ depending on size, weight, and location.

Not every build needs all of the above, but including a buffer for these items helps avoid budget surprises and downtime.

Factors That Move the Price Up or Down

Several variables explain why two similar-looking header sets can have very different price tags—and why installation quotes can vary.

• Material: 304 stainless costs more but resists corrosion better than 409 stainless or mild steel.
• Coating: Ceramic-coated headers run hotter inside (good for flow) and cooler outside (good for under-hood temps), but cost more.
• Brand/fitment quality: Premium brands generally fit better, include better hardware, and last longer.
• Emissions compliance: CARB-legal headers carry development and certification costs; not all model years are covered.
• Truck packaging: 4WD, larger frames, and tight engine bays add labor time; rust dramatically increases difficulty.
• Local labor rates: Urban/coastal areas and performance shops typically charge more.
• Supply chain and demand: Stainless prices and brand availability can shift retail pricing.
• New vs used: Used headers can be $150–$600 but may have warped flanges, stripped threads, or missing hardware.

Balancing material, brand, and legal status against your budget and climate will usually deliver the best long-term value.

Diesel Trucks: A Different Story

Most diesel pickups use cast manifolds and up-pipes rather than tubular “headers.” Upgraded diesel manifolds/up-pipes typically run $400–$1,200 in parts, with installation often $400–$1,000 depending on platform and rust. True tubular headers are uncommon on modern diesels used on-road.

Performance and Legality Notes

Shorty headers on a stock or lightly modified gas truck often yield modest gains (roughly 5–15 hp), improved throttle response, and a deeper tone. Long-tubes can add more mid-to-top-end power (15–35+ hp with a tune) and a louder exhaust note. Always verify emissions legality where you live: it’s illegal in the U.S. to remove or tamper with catalytic converters on road-driven vehicles, and CARB states require parts with an Executive Order (EO) number. Tunes can optimize air/fuel and avoid check-engine lights with long-tube setups but should be emissions-compliant.

Budgeting Scenarios

If you’re planning a project and want rough “all-in” scenarios, use the guide below to set expectations.

• Value build (shorty headers, DIY or low labor): $600–$1,200 total.
• Enthusiast build (long-tubes, pro install, no cats): $1,200–$2,200 total; add $300–$700 if tuning is needed.
• Premium build (304 stainless long-tubes, ceramic, catted, tune): $1,800–$3,200+ total.

These tiers cover most gas half-ton trucks; heavier-duty or rare applications may trend higher, especially with emissions-compliant catted systems.

How to Save Without Regretting It

There are smart ways to trim costs while preserving reliability and compliance.

• Pick 409 stainless to save vs 304, and add ceramic coat later if needed.
• Reuse factory cats and O2 sensors when legal and in good condition.
• Pre-soak manifold hardware with penetrating oil days in advance to cut labor time.
• Coordinate header install with manifold bolt repair to consolidate labor.
• Buy during seasonal sales; confirm kits include gaskets, hardware, and O2 extensions.

Focusing on fitment quality and emissions compliance usually pays off more than chasing the lowest sticker price.

Bottom Line

For most gas trucks, expect $300–$800 for shorty headers or $700–$1,800 for long-tubes, plus $300–$1,200+ to install. Premium, catted systems and tuning push total costs into the $1,800–$3,200+ range. Prices are highly dependent on material, brand, emissions legality, and your truck’s condition.

Summary

Headers for trucks range from roughly $200–$2,000 for parts, with complete installed costs commonly $600–$3,200+. Shorties are the budget-friendly, emissions-easier option; long-tubes deliver bigger gains but cost more and often need tuning. Material, coatings, brand, CARB compliance, and labor complexity drive the final bill. Diesel trucks usually use manifolds/up-pipes instead of tubular headers, with different pricing. Plan for gaskets, hardware, and potential O2/tune add-ons to avoid surprises.

Are headers really worth it?

Headers are worth it for performance-focused vehicles and can improve horsepower, torque, and fuel economy by reducing engine back pressure and improving scavenging, though the exact gains depend on header type and engine tuning. Long tube headers generally offer the greatest performance gains for racing applications but require significant tuning and can be costly. Shorty or mid-length headers are a more practical option for daily drivers, providing a modest increase in low-to-mid-range torque and a better exhaust note without the complications of long tubes.
 
This video explains how exhaust headers are designed to improve engine performance by reducing back pressure and enhancing exhaust scavenging: 57sDonutYouTube · Jun 24, 2020
Benefits of Headers

• Increased Power: Headers can lead to more horsepower and torque by allowing the engine to “breathe” more efficiently, clearing out exhaust gasses faster. 
• Improved Fuel Economy: A more efficient engine can result in better fuel consumption because the engine doesn’t have to work as hard to expel exhaust gases. 
• Enhanced Sound: Headers can change the exhaust note, often resulting in a smoother, more aggressive, or more defined sound compared to stock manifolds. 
• Better Scavenging: Properly designed headers create negative pressure waves that help pull remaining exhaust gasses out of the cylinders, allowing for more fresh air and fuel to enter. 

Considerations

• Engine Type: Headers are most beneficial for performance vehicles with a larger focus on high RPM operation. A well-designed stock exhaust manifold may already be optimized for a non-performance engine. 
• Header Type:
  • Long Tube Headers: Offer the most significant performance gains and are ideal for racing, but are harder to install and require proper ECU tuning. 
  • Shorty Headers: Provide a smaller, more manageable performance increase with better low-to-mid-range torque, making them a good choice for daily driving. 
• ECU Tuning: Installing headers, especially long tube headers, changes the air-fuel ratio, requiring an engine tune to take full advantage of the new exhaust flow and prevent potential damage. 
• Cost vs. Gain: High-end headers can be expensive, and the performance gains may not be significant enough to justify the cost on a stock or mildly modified engine. 

Are they worth it for you?

• For Performance Enthusiasts: If your goal is maximum horsepower and you are willing to invest in tuning and accept a potentially more aggressive vehicle operation, headers are likely worth the investment. 
• For Daily Drivers: A shorty header might be a good option if you want a modest performance boost, improved exhaust sound, and don’t want the complications of long tube headers. 
• For Most Street-Driven Cars: The benefits of headers on a stock, street-driven car may be minimal, and you might not see enough performance improvement to justify the cost. 

What size headers for 500 hp?

1 3/4 to 2 inches
However, for a street car, Don recommends the following guidelines: 200-325 horsepower look for 1 1/2-inch primaries, 275-425 horsepower use 1 3/4-inches, 400-500 horsepower opt for 1 3/4 to 2 inches, and 500+ horsepower look for 2 inches or greater. Keep in mind, smaller pipes mean more low-to-mid-range torque.

How much HP will headers add?

Headers typically add 10 to 30 horsepower, though the exact gain varies based on the engine, type of headers, other modifications, and vehicle tuning. Long-tube headers generally offer more significant power gains than shorty headers by reducing exhaust restriction more effectively. For maximum benefit, headers should be combined with supporting modifications like a cold air intake or camshaft upgrade and should be followed by an engine tune to match the new exhaust system. 
Factors influencing horsepower gains:

• Header Type: Long-tube headers improve exhaust flow more than shorty headers, leading to greater power gains, particularly at higher RPMs. 
• Engine Type and Setup: Larger engines or those already tuned for performance will see more substantial gains. 
• Supporting Modifications: When combined with other parts like a cold air intake or a more aggressive camshaft, headers can provide much larger horsepower increases. 
• Engine Tuning: An engine tune (ECU remapping) is crucial to optimize performance with new headers, fully unlocking their potential and ensuring the engine runs efficiently. 

Expected gains by header type:

• Long-tube headers: Opens in new tabCan provide gains of 15 to 30 horsepower, sometimes even more, especially when supported by tuning and other mods. 
• Shorty headers: Opens in new tabOffer more modest gains, around 10 to 15 horsepower, and provide benefits in low-end torque and throttle response rather than large peak power increases. 

What to expect beyond peak horsepower:
Headers provide other benefits, such as improving the engine’s volumetric efficiency by allowing it to “work less hard” to expel exhaust gases. This leads to increased torque, better throttle response, and a more aggressive exhaust note.

How much do headers usually cost?

On average, headers for a typical vehicle can range from $200 to $1,500 or more. If you opt for a complete headers exhaust system, including other components like a high-flow catalytic converter and performance mufflers, the cost can increase further.