How much does it cost to replace the exhaust system?

For most U.S. vehicles in 2025, replacing an exhaust system typically costs $600–$1,700 for a cat-back setup, $1,200–$3,500+ if catalytic converters are included, and $2,000–$6,000 for multi-converter, hybrid, diesel, or European luxury models. The final price depends on your vehicle, local emissions rules (especially in California), materials (aluminized vs stainless), and labor rates. Below is a clear breakdown of what “exhaust replacement” includes, typical price ranges, and how to avoid overpaying.

What counts as “replacing the exhaust system”

“Exhaust replacement” can mean anything from swapping the rear muffler to installing a full system from the engine manifold to the tailpipe. The scope determines both parts and labor costs.

• Axle-back: Replaces the muffler(s) and tailpipes behind the rear axle.
• Cat-back: Replaces everything from the catalytic converter(s) back (mid-pipes, resonator, muffler, tailpipes).
• Manifold-back: Replaces from the exhaust manifold outlet or downpipe to the tailpipe (often excludes the manifold itself).
• Full system with catalytic converters: Includes converters and all pipes/resonators/mufflers; may include manifold if integrated with a converter.
• Turbo-back (turbo vehicles): From the turbo outlet through to the tailpipe.
• Section repair: Targeted replacement of a rusted pipe, flange, flex joint, or muffler.

Shops will quote based on the starting point (axle, converter, manifold, or turbo) and which emissions components are included.

Typical price ranges in 2025

These ballpark figures reflect mainstream U.S. parts and labor before taxes/shop fees; coastal metros with higher labor rates often run 15–40% more.

• Axle-back: $250–$900 parts + $120–$300 labor (0.7–1.5 hours) = $370–$1,200 total.
• Cat-back: $400–$1,200 parts + $180–$500 labor (1.5–3.0 hours) = $600–$1,700 total.
• Full system without converters: $800–$2,000 total, depending on pipes, resonator, muffler, and custom work.
• Full system with catalytic converters: $1,200–$3,500+ for most cars; $2,000–$6,000 for vehicles with multiple or CARB-compliant converters (common on V6/V8, hybrids, and many European models).
• Diesel (DPF/SCR systems): $2,500–$5,500+ depending on whether diesel particulate filter and/or SCR catalyst/DEF components are replaced.
• Performance stainless (304) or custom-fabricated systems: $1,000–$3,000+, driven by material and fabrication time.

Expect the low end for simple, rust-free jobs on common models, and the high end for complex packaging, premium materials, or stringent emissions compliance.

Component-by-component cost breakdown

If you’re not replacing the whole system, these typical parts costs can help you evaluate a line-item estimate.

• Muffler: $80–$400.
• Resonator: $75–$300.
• Mid/tail pipes (sectioned): $100–$500.
• Exhaust manifold (without cat): $200–$900; with integrated cat: $900–$2,500.
• Catalytic converter: $200–$700 for basic federal aftermarket; $800–$2,500 each for CARB-compliant units; many cars use 2+ converters.
• Oxygen sensors: $60–$250 each (some cars have 2–4).
• Flex pipe: $60–$300.
• Gaskets/hardware/hangers/clamps: $20–$120 total per job.
• Heat shields or replacement brackets: $30–$150.
• Exhaust tips/finishers (optional): $30–$150.

The mix of parts—especially the number and type of catalytic converters—drives most of the cost variation across vehicles.

Labor time and rates

Labor depends on vehicle packaging, rust/corrosion, and whether welding or custom fabrication is needed. U.S. labor rates typically range from $100–$150/hour at independent shops and $150–$250/hour at dealerships.

• Axle-back: 0.7–1.5 hours.
• Cat-back: 1.5–3.0 hours.
• Exhaust manifold (non-integrated): 2–5 hours; longer on AWD/turbo models.
• Full system with converters: 3–8 hours, depending on rust and complexity.
• Rust-belt adders: +0.5–2.0 hours for seized fasteners, broken studs, or heavy corrosion.
• Custom fabrication: +1–3 hours for bending/welding and fitment.

Shops often add modest shop-supplies and disposal fees; ask for an out-the-door total to avoid surprises.

Factors that move the price up or down

Understanding these drivers helps explain why two similar-sounding jobs can be hundreds or thousands of dollars apart.

• Emissions standard: CARB-compliant catalytic converters (CA, NY, CO, etc.) cost substantially more than federal units.
• Number of converters: V6/V8, hybrids, and some European models use multiple converters and O2 sensors.
• Material: Aluminized steel is cheaper; 409 stainless offers better longevity; 304 stainless costs most but lasts longest.
• OEM vs aftermarket: OEM generally fits best but costs more; reputable aftermarket can save 20–50%.
• Rust/corrosion: Rust-belt vehicles often need extra parts and labor for seized hardware or rotten flanges.
• AWD/turbo/packaging: Tighter underbodies mean more labor.
• Sensors and hardware: Additional O2 sensors, gaskets, hangers, and clamps add up.
• Warranty and brand: Longer warranties and premium brands raise parts prices.
• Shop type and location: Dealerships and high-cost metros charge higher labor rates.
• Insurance: For catalytic-converter theft, comprehensive coverage may offset much of the cost (minus deductible).

If your quote seems high, check whether it includes CARB-compliant parts, additional sensors, or manifold-integrated converters.

Quick real-world estimates by vehicle segment

These ballpark totals assume mainstream brands and typical labor; actual quotes vary by region and emissions compliance.

• Economy compact (4-cyl): Cat-back $650–$1,100; full with converters $1,300–$2,400.
• Midsize SUV (V6): Cat-back $800–$1,400; full with converters $2,000–$3,800.
• Full-size pickup (V8): Cat-back $900–$1,600; full with dual converters $2,200–$4,500.
• European luxury (BMW/Mercedes/Audi): Cat-back $1,200–$2,500; with converters $3,000–$6,000.
• Hybrid (two+ converters): $1,600–$4,000 depending on CARB requirements.
• Light-duty diesel (DPF/SCR): $2,500–$5,500+ when emissions aftertreatment is replaced.

Use these ranges as a starting point; request itemized quotes with part numbers to compare apples to apples.

When replacement is unavoidable vs repair

Not every noisy exhaust requires a full system. Some issues can be repaired cheaply; others demand replacement for safety, legality, or durability.

• Replace if: Catalytic converters are stolen/failing, pipes or muffler are rusted-through, flanges are disintegrated, or the flex joint is torn.
• Repair if: There’s a small leak at a flange or seam, a hanger has broken, or a short section of pipe can be spliced or welded.
• Compliance note: Tampering with or “gutting” converters is illegal; use EPA- or CARB-compliant parts as required in your state.

A reputable shop will show you the damaged sections and explain whether a targeted repair is safe and legal.

How to save money without cutting corners

Smart choices can trim costs while preserving safety, durability, and emissions compliance.

• Get 2–3 itemized quotes with part numbers and warranty terms.
• Ask about certified aftermarket converters (EPA/CARB) instead of OEM if allowed.
• Choose aluminized steel for budget, 409 stainless for balanced longevity, or 304 for long-term ownership.
• Consider a bolt-on cat-back kit instead of full custom fabrication when possible.
• Bundle related work (O2 sensors, gaskets, hangers) to save on repeat labor.
• Verify parts and labor warranties (many cat-backs: 1–3 years; stainless often longer; converters vary widely).
• For converter theft, file a comprehensive insurance claim and install a theft shield afterward.
• Avoid ultra-cheap “universal” converters that may trigger check-engine lights or fail emissions.

Always confirm that any quoted converter is legal for your state and engine family to pass inspection.

What to ask your shop

Clear questions help you gauge value and avoid surprise costs.

• Does the quote cover axle-back, cat-back, or a full system including converters/manifold?
• Which part numbers/brands and materials are being used? Are converters EPA or CARB compliant?
• What are the labor hours, hourly rate, and the out-the-door total including taxes/fees?
• Will joints be clamped or welded? Are new gaskets, hangers, and hardware included?
• Are O2 sensors included or reused, and will any seized studs be extra?
• What are the warranties on parts and labor, and who handles claims?

Get the details in writing; it simplifies comparisons and protects you if problems arise later.

Timeline, drivability, and safety

Exhaust issues range from annoying to hazardous. Timing and safety depend on what’s broken.

• Job time: 1–3 hours for cat-back; 3–8 hours for full systems with converters/manifold.
• Drivability: Loud but drivable for minor leaks; unsafe if exhaust fumes can enter the cabin or parts are hanging loose.
• Legal/emissions: Check-engine lights from converter or O2 faults can fail inspection; excessive noise can violate local laws.
• Recommendation: If a pipe is dragging, a converter is missing, or fumes are entering the vehicle, arrange a tow.

Safety should trump convenience—exhaust leaks can introduce carbon monoxide into the cabin.

Bottom line

Expect $600–$1,700 for a typical cat-back and $1,200–$3,500+ when catalytic converters are involved, with complex or premium vehicles reaching $2,000–$6,000. Confirm the scope, emissions compliance, materials, labor hours, and warranties to get a fair, durable repair.

Summary

Exhaust replacement costs vary widely by scope and emissions requirements. Cat-back jobs often land between $600 and $1,700, while full systems with catalytic converters commonly run $1,200–$3,500+ and can exceed $4,000 on multi-converter, hybrid, diesel, or European vehicles. Labor runs 1.5–8 hours depending on complexity and rust, and parts choices (aluminized vs stainless, OEM vs aftermarket, CARB compliance) heavily influence price. Get itemized quotes, confirm legality for your state, and prioritize safety and warranty coverage.

Is it expensive to replace an exhaust?

Exhaust repairs are cheaper but may be short-term, while replacements provide a long-lasting solution. Repairs usually fix specific issues like leaks or damaged parts and cost between £100 and £400. Replacements involve swapping larger sections or the entire system, costing £300 to over £1,000.

Can you drive a car with a bad exhaust system?

No, you generally cannot and should not drive with a broken exhaust, as it creates significant risks including exposure to dangerous carbon monoxide fumes inside the vehicle, potential fire hazards, increased pollution, reduced engine performance, loud and distracting noises, and the possibility of the exhaust falling off completely, leading to further damage and safety issues. You should have the vehicle towed to a repair shop as soon as possible.
 
Health & Safety Risks

• Carbon Monoxide Poisoning: Opens in new tabA broken exhaust allows poisonous and odorless carbon monoxide gas from the engine to enter the passenger cabin through the ventilation system, which can lead to unconsciousness or death. 
• Fire Hazard: Opens in new tabA leak can allow oxygen to enter the exhaust system, increasing the temperature and potentially causing a fire under the car’s engine. 
• Exhaust Falling Off: Opens in new tabA damaged or loose exhaust pipe could detach and drag on the ground, posing a hazard to your vehicle and others, and potentially tearing the entire system off. 

Vehicle & Engine Issues

• Reduced Engine Performance: A broken exhaust system disrupts the engine’s pressure regulation and air-fuel balance, leading to poor acceleration, rough idling, and reduced power. 
• Increased Fuel Consumption: The disruption can cause the engine to work harder, resulting in decreased fuel efficiency. 
• Damage to Other Components: Excessive heat and vibrations from a severe leak can damage nearby wiring, hoses, or other underbody components. 

Legal & Environmental Concerns

• Illegal Emissions: Excessive emissions from a damaged exhaust can be illegal in some areas, potentially leading to fines. 
• Legal Penalties: Driving a vehicle with a loud, unroadworthy exhaust can also attract unwanted attention from law enforcement and result in summons and fines. 

What to Do 

• Get it Towed: Do not risk driving the vehicle. Have it towed to a professional auto repair shop immediately.
• Contact a Professional: A mechanic can properly diagnose and repair the broken exhaust system to prevent further problems.

How much does it cost to replace a whole exhaust system?

Replacing a complete exhaust system can cost anywhere from $300 to over $2,000, with a typical range of $500 to $1,500 for common vehicles, not including the exhaust manifold or catalytic converter. The final price depends on your vehicle’s make and model, the quality of the replacement parts, the labor costs in your area, and the extent of the damage. High-performance or luxury vehicles can incur higher costs, and prices will also increase if components like the catalytic converter or exhaust manifold need replacement. 
Factors influencing the cost:

• Vehicle Type: Luxury or performance cars require more expensive parts and labor. 
• Part Quality: Higher-quality parts, such as stainless steel, or brands like Borla, will be more expensive but offer better durability. 
• Labor Costs: Local labor rates can vary significantly, affecting the overall price. 
• Extent of Damage: A full system replacement is more costly than a single part. 
• High-Cost Components:
  • Catalytic Converter: This is a major component and can add $150 to $300 or more to the cost. 
  • Exhaust Manifold: Replacing this part can be one of the most expensive repairs, with costs around $500 or more. 

How to get an accurate estimate:

1. Consult a Mechanic: Opens in new tabA mechanic can diagnose the specific problem and provide an accurate quote. 
2. Compare Prices: Opens in new tabCheck prices at different exhaust shops to find the best deal in your area. 
3. Consider the Muffler Shop: Opens in new tabLocal muffler shops or national chains can be a good option, but research part quality and warranty to ensure longevity. 

Is it worth it to replace an exhaust?

If you are looking for improved performance, sound, and aesthetics, and you are willing to invest in the upgrade, an exhaust system upgrade can be worth it. However, consider your specific needs, budget, and any legal implications before making a decision.