The Borla S-Type exhaust system for the Dodge Challenger has earned a reputation as one of the most sought-after aftermarket upgrades for muscle car enthusiasts. It combines a signature aggressive tone with measurable performance gains, all while maintaining the durability expected from a premium brand. Whether you are a weekend warrior looking to wake up your Hemi or a daily driver seeking a more engaging experience, the Borla S-Type delivers. In this comprehensive guide, we will break down the system’s features, sound characteristics, installation process, and maintenance tips to help you make an informed decision.

What Makes the Borla S-Type Challenger Exhaust Stand Out?

The Borla S-Type is part of Borla’s broad exhaust lineup, sitting between the more subdued Touring system and the aggressive ATAK (Acoustically Tuned Applied Kinetics) option. It offers a balance of deep resonance and controlled volume, making it a favorite for those who want a noticeable yet livable upgrade.

Construction and Materials

Every Borla S-Type system is constructed from T-304 stainless steel, the highest grade of stainless steel commonly used in exhaust manufacturing. This material resists rust and corrosion far better than 409 stainless steel or aluminized steel, especially in climates where road salt is used. The mandrel-bent tubing ensures smooth gas flow and maintains the pipe’s full diameter through every bend, which directly contributes to horsepower gains.

The mufflers feature Borla’s patented Reflex technology—a straight-through design with internal chambers that cancel out harsh frequencies. This design reduces interior drone while preserving the deep, external rumble. The system is fully welded (not crimped) and comes with a limited lifetime warranty for the original purchaser, reflecting Borla’s confidence in its longevity.

Performance Gains

While the exact horsepower and torque figures depend on your Challenger’s engine size and existing modifications, Borla engineers the S-Type to reduce backpressure and improve exhaust scavenging. Independent dyno tests on 5.7L and 6.4L Hemi engines typically show gains of 8–15 horsepower and 10–15 lb-ft of torque. These gains are most noticeable in the mid-to-upper RPM range, where the Hemi naturally produces peak power.

It is important to note that the S-Type exhaust is designed as a cat-back system, meaning it replaces the exhaust from the catalytic converters back. This makes installation straightforward and avoids potential issues with emissions compliance in street-legal configurations.

The Borla S-Type Signature Sound

The sound of the S-Type is often described as a deep, throaty growl that intensifies under hard acceleration without becoming obnoxious. This is achieved through a combination of pipe diameter, muffler design, and internal tuning. Below are the key sound characteristics:

  • Aggressive Idle: At idle, the exhaust produces a distinct low-frequency rumble that signals the V8’s presence without shaking the neighborhood.
  • Wide-Open Throttle: When you stomp the gas, the S-Type unleashes a full-bodied roar. It is louder and more assertive than the stock system but still smooth—unlike some straight-pipe setups that sound harsh.
  • Drone Mitigation: Borla engineers use Helmholtz resonance tuning inside the muffler to cancel specific frequencies that cause interior drone. On the highway, the S-Type remains comfortable; the exhaust note fades into the background at cruising speeds.
  • Unique Sound Signature: The S-Type has a slightly higher pitch than the Touring system but is deeper and less raspy than the ATAK. It is the Goldilocks option for many Challenger owners.

For a live demonstration, you can listen to the S-Type on a 6.4L Scat Pack on Borla’s official product page. (We recommend the Borla S-Type for Challenger page on their website).

Installation Guide for the Borla S-Type Challenger Exhaust

Installing the Borla S-Type system is a weekend-friendly project for DIY enthusiasts with moderate mechanical skill. The entire job can typically be completed in 2–4 hours, assuming no rusted or seized hardware. Below is a step-by-step breakdown.

Tools and Supplies Needed

  • Socket set (metric and SAE; 10mm, 13mm, 15mm, 18mm are common)
  • Ratchet with extension bars
  • Wrenches (combination wrenches for hard-to-reach nuts)
  • Jack and two jack stands (or a vehicle lift)
  • Penetrating oil (e.g., WD-40, PB Blaster)
  • Exhaust hanger removal tool or large flathead screwdriver
  • Floor jack for supporting the exhaust during removal
  • Torque wrench (to tighten clamps to spec)
  • Rubber mallet (to free stubborn hangers)

Preparation and Safety

Work on a level surface and use jack stands—never rely on a jack alone. Chock the front wheels to prevent rolling. Allow the exhaust to cool completely if the car was driven previously. Apply penetrating oil to all exhaust flange bolts and hanger rubber inserts 30 minutes before starting.

Removing the Factory Exhaust

Begin by loosening the bolts that connect the mid-pipe to the rear catalytic converter flanges. These are usually 15mm bolts. If they resist, soak them again and use a breaker bar. Next, remove the rubber hangers that hold the rear muffler and tips. An exhaust hanger removal tool makes this easier, but a flathead screwdriver can also work—just be careful not to tear the rubber. Lower the factory exhaust sections using the floor jack to avoid dropping them. Some Challenger models have a single-piece rear section; others have separate mufflers. In either case, work from the back forward.

Installing the Borla S-Type System

Borla provides detailed instructions with each system. The general process is:

  1. Dry fit the system before tightening any clamps. Assemble the pieces loosely from the front (downpipes/catalytic converter connection) to the rear (tips). This allows you to adjust alignment so tips sit centered in the bumper cutouts.
  2. Attach the front pipe to the existing catalytic converter flanges using the provided gaskets and bolts. Torque to Borla’s specification (typically 35–40 ft-lb).
  3. Connect the intermediate pipe using the supplied band clamps. Do not fully tighten yet—keep them snug but adjustable.
  4. Install the rear muffler and tips. Slide the tips onto the muffler outlets and adjust for desired appearance. The S-Type tips are polished T-304 stainless and add an aggressive look.
  5. Reattach the rubber hangers to the factory mounting points on the underbody. Borla includes polyurethane bushings or uses the stock rubber hangers depending on the kit.
  6. Check clearance all along the exhaust path. Ensure no contact with the underbody, heat shields, or driveshaft. Rotate the pipes slightly if needed.
  7. Torque all clamps and flanges to spec. A loose clamp can cause leaks or a rattling sound.

Post-Installation Checks

Start the engine and let it idle. Listen for exhaust leaks at each joint—use a gloved hand to feel for escaping gas. If you hear ticking, tighten the clamps further. Take a short test drive to confirm the sound is as expected and that there are no vibrations. After the first 100 miles, re-check the clamp torque, as the exhaust components will seat and settle.

For a visual walkthrough, many Challenger owners share installation videos on forums. A highly regarded resource is the Challenger Talk forums, where you can find community tips for your specific model year.

Maintenance and Longevity

The T-304 stainless steel construction means the Borla S-Type will outlast the car in most cases. However, a few simple maintenance steps will keep it looking and sounding its best:

  • Clean the tips regularly with a stainless steel polish (e.g., Mother’s Mag & Aluminum Polish) to remove baked-on brake dust and road grime.
  • Inspect clamps annually and re-torque if necessary. Vibration can loosen them over time.
  • Check for leaks at gasket flanges, especially after the first few temperature cycles.
  • Protect against salt if you drive in winter. While T-304 is highly corrosion-resistant, road salt can still leave stains. A light rinse under the car after salty drives helps.

Warranty coverage is provided by Borla for the original purchaser; keep your receipt and any proof of purchase. The limited lifetime warranty covers defects in materials and workmanship but does not cover damage from improper installation or off-road use.

Compatibility and Fitment Notes

Borla offers the S-Type cat-back system for nearly every Challenger engine configuration, including the 3.6L V6, 5.7L Hemi, 6.4L (392) Hemi, and the supercharged 6.2L Hellcat. However, fitment varies slightly by model year and suspension setup. Here are key points:

  • 2015–2023 Challengers share a common exhaust layout, so systems are generally interchangeable.
  • Hellcat models have slightly different hanger positions due to the larger supercharger and intercooler. Always verify the part number for your specific engine.
  • If your Challenger has an active exhaust (with valves), the Borla S-Type may include adapters to retain the valve functionality or a delete option. Check product descriptions carefully.
  • Some systems require cutting the factory exhaust behind the resonator or the muffler. Borla’s standard S-Type cat-back is a full bolt-in replacement, no welding required.

For a complete list of compatible part numbers, visit Borla’s official website and use their vehicle selector tool. You can also check retailers like Summit Racing for user reviews and fitment notes specific to your Challenger edition.

Cost and Value

The Borla S-Type is a premium product, with prices typically ranging from $1,200 to $1,800 depending on the engine and whether you choose the standard cat-back or an axle-back version. While this is significantly more than budget brands, the lifetime warranty, T-304 construction, and proven sound quality make it a long-term investment. Many owners report that the improved driving experience and added resale value justify the price.

Customer Feedback and Real-World Impressions

On forums and review sites, the Borla S-Type consistently receives high marks. Common praise includes the lack of drone, the deep idle, and the clean fitment. A few owners mention that the system can be slightly louder than expected under full throttle (especially on the 6.4L). That said, the majority agree that it is the best-sounding option for daily drivers who want an aggressive edge without constant fatigue on the highway.

For additional perspectives, check the Challenger Talk community—there is a dedicated thread with hundreds of posts comparing the S-Type to other brands.

Conclusion

The Borla S-Type Challenger exhaust system delivers on every front: a signature aggressive sound that avoids drone, measurable performance gains, and rugged T-304 stainless steel construction backed by a limited lifetime warranty. With careful installation following the tips above, your Challenger will not only sound better but also benefit from improved throttle response and a more joyful driving experience. Whether you choose to DIY or have a shop install it, the S-Type remains one of the most rewarding upgrades you can make to your Mopar muscle car.