How Much Is Exhaust Work? Current Prices, What Affects Them, and How to Budget

Expect most exhaust repairs in the U.S. to run roughly $200–$900, with minor weld fixes as low as $75–$200 and catalytic converter replacements commonly $900–$2,500 or more depending on the vehicle and emissions requirements. Final price depends on the part being serviced (muffler, flex pipe, cat, manifold), labor rates in your area, rust/corrosion, materials (aluminized vs. stainless), and whether emissions-compliant parts are required.

What Falls Under “Exhaust Work”

Exhaust work covers everything from small leak repairs to full system replacements. Understanding which component needs attention helps narrow the price range and speed up your quote.

• Muffler and resonator: Reduce sound and drone.
• Pipes and flex sections: Direct flow and allow engine movement.
• Catalytic converter(s): Reduce emissions; often the costliest component.
• Exhaust manifold/header: Collect gases from the engine cylinders.
• Oxygen (O2) sensors: Monitor emissions and fuel mixture.
• Gaskets, clamps, hangers: Seals and supports that often fail with age.
• Cat-back/axle-back systems: Performance or replacement assemblies from the catalytic converter rearward.

Pinpointing the faulty section—whether by inspection, code scan, or smoke test—helps avoid replacing more than necessary and keeps costs predictable.

Typical Price Ranges in the U.S. (2025)

These ballpark figures reflect common passenger vehicles. Prices trend higher for luxury models, rust-belt vehicles, and parts with strict emissions compliance (e.g., CARB states). They can be lower in regions with cheaper labor or on vehicles with easy access and minimal corrosion.

• Weld/patch a small leak: $75–$200
• Hangers, clamps, gaskets: $40–$150 installed (per item/area)
• Muffler replacement (standard): $150–$450 parts and labor
• Resonator replacement: $200–$600
• Flex pipe/front pipe section: $250–$900
• Exhaust pipe fabrication/replacement (per section): $150–$400
• Oxygen sensor: $120–$350 each installed
• Exhaust manifold (non-integrated): $400–$1,500 installed
• Catalytic converter (typical non-CARB): $900–$2,500 installed
• Catalytic converter (vehicles with expensive OE or CARB-compliant units, e.g., hybrids/late models): $1,800–$3,500+
• Axle-back kit: $250–$700 parts + $100–$200 labor
• Cat-back system (aftermarket): $350–$1,200 parts + $150–$300 labor
• Custom stainless system (mandrel-bent): $800–$2,000+
• Headers/header-back performance systems: $1,000–$2,500+ installed

Add sales tax, shop supplies, and environmental/disposal fees—often 5–12% of the parts and labor total—to estimate your out-the-door price.

Labor Rates and Typical Time

Labor drives much of the cost. Rates and book times vary by location, vehicle, and corrosion level.

• Independent shop labor: ~$95–$165/hour; dealers: ~$140–$250/hour; mobile welder: ~$85–$140/hour
• Time guides (ballpark): muffler 0.7–1.5 hr; resonator 0.8–1.6 hr; flex pipe 1.5–3.0 hr; catalytic converter 1.0–3.0 hr; O2 sensor 0.5–1.0 hr; manifold 3–8 hr

Rust-belt vehicles and seized hardware can add significant time; expect contingencies to be noted on your estimate if corrosion is present.

What Most Affects the Price

Several variables can swing an exhaust estimate by hundreds or thousands of dollars. Knowing them helps explain why quotes differ between shops.

• Vehicle and engine: Tight packaging, turbocharging, and multi-cat layouts raise costs.
• Emissions rules: CARB-compliant catalytic converters (e.g., in CA, NY, CO, ME) cost more but are legally required.
• Rust/corrosion: Extra labor for seized fasteners and potential need for additional parts.
• Materials: Stainless steel lasts longer and costs more than aluminized steel.
• OEM vs. aftermarket: OEM often fits best; quality aftermarket can save money if compliant.
• Availability and theft trends: High-theft models (e.g., some hybrids) drive up converter prices and lead times.
• Noise laws and inspections: Loud systems or emissions tampering can fail inspection and incur fines.

For the most reliable budgeting, ask shops to specify materials, brand, and compliance status on the quote and to note rust-related contingencies.

Diagnostics and When You Need Exhaust Work

Symptoms and straightforward tests can determine whether you need repair or replacement—and which part.

• Common signs: louder exhaust, rattling, exhaust smell, visible leaks, hanging pipes, poor fuel economy, check-engine light (P0420/P0430/P013x/P015x).
• Basic scan/inspection: Often free to $60; advanced diagnostic/smoke test: $60–$180.
• Emissions or safety retest fees (where applicable): $15–$40.

Clear diagnostics reduce guesswork and help avoid replacing good components, especially around O2 sensors and catalytic efficiency codes.

Real-World Estimate Scenarios

Here are typical out-the-door examples to illustrate how parts, labor, and conditions affect what you pay.

1. Small weld patch on a mid-pipe leak (Sun Belt, minimal rust): $120–$180, same-day.
2. Muffler replacement on a compact sedan with bolt-on part: $260–$420 including clamps, hanger, and tax.
3. Flex pipe replacement on an AWD crossover (rust-belt): $520–$900 due to cutting, welding, and extra hardware.
4. Catalytic converter replacement after theft on a hybrid in a CARB state: $1,900–$3,300 with CARB cat, new O2 sensor, and anti-theft shield.

Your totals may vary with brand selection, local labor rates, and rust. Always request an itemized estimate before authorizing work.

Getting an Accurate Quote

A few specifics in your request help shops price the job quickly and precisely.

• Provide VIN, mileage, and a clear description of symptoms; include photos of the damaged area if visible.
• Ask for an itemized, out-the-door estimate: parts (brand/material/compliance), labor hours and rate, taxes/fees.
• Confirm emissions compliance (CARB/50-state) and noise legality for your state.
• Request warranty terms on parts and labor and whether old parts will be returned.
• Get 2–3 quotes, especially for catalytic converters and custom work.

These steps reduce surprises and make it easier to compare apples-to-apples between shops.

Warranty and Legality

Exhaust components carry different protections—and legal obligations—especially around emissions controls.

• OEM catalytic converters: Federal emissions warranty up to 8 years/80,000 miles for certain components; check your vehicle’s coverage.
• Aftermarket converters: Commonly 2–5 years on the shell/structure; efficiency warranties vary.
• Mufflers/exhaust kits: Some brands offer limited lifetime against rust-through (parts only).
• Legal note: Removing or tampering with emissions equipment is illegal; non-compliant cats can fail inspection and incur fines.

Verify written warranty coverage and ensure parts meet your state’s emissions and inspection standards before installation.

Timeline and Preparation

Turnaround depends on parts availability, rust, and fabrication needs.

• Minor repairs: 0.5–1.5 hours; many done same-day.
• Muffler/resonator/pipe sections: same day if parts are in stock.
• Catalytic converters/manifolds: 1–2 days if parts must be ordered; longer for CARB or OE units.
• Custom systems: half to full day of fabrication; schedule in advance.

Ask about part lead times and plan for potential delays if your vehicle shows significant corrosion or requires special-order components.

Bottom Line

Budget a few hundred dollars for common exhaust repairs and over $1,000 if a catalytic converter or manifold is involved—especially on newer, hybrid, or CARB-state vehicles. Strong diagnostics, itemized quotes, and verifying emissions compliance are the best ways to control cost and avoid repeat work. Prices outside the U.S. will vary by currency, taxes, labor rates, and local regulations.

Summary

Most exhaust jobs cost $200–$900; minor welds can be under $200, while catalytic converters typically run $900–$2,500+ depending on vehicle and emissions compliance. Labor rates, rust, materials, and local laws drive variation. Get an itemized, out-the-door estimate that specifies brand, material, and legal compliance, and compare multiple quotes—especially for catalytic converters and custom systems.