Introducing the Borla Cat-Back Exhaust for the Ram 1500

Upgrading the exhaust system on a Ram 1500 is one of the most popular modifications for owners seeking a stronger performance feel and a more assertive exhaust note. Among aftermarket options, Borla stands out for its American-made quality, mandrel-bent T-304 stainless steel construction, and a range of sound profiles that suit different driving styles. The Borla cat-back exhaust system is engineered to reduce backpressure, improve scavenging, and deliver a genuine horsepower gain—often quoted in the range of 12 HP for the Ram 1500. This article provides a comprehensive look at the cost, installation process, performance benefits, and real-world considerations when adding a Borla cat-back system to your truck.

Understanding the Borla Cat-Back Exhaust System

Borla offers three primary sound levels for the Ram 1500: the Touring (mild), S-Type (moderate), and ATAK (aggressive). All systems are constructed from aerospace-grade T-304 stainless steel and feature mandrel-bent tubing to eliminate flow restrictions. The cat-back configuration replaces everything from the catalytic converter back to the exhaust tips, making it a direct bolt-on upgrade that requires no welding or cutting when properly installed. Key design elements include:

  • Mandrel-bent tubing – ensures consistent internal diameter for maximum exhaust flow and horsepower gains.
  • Multi-core straight-through mufflers – reduce backpressure while producing a tuned sound.
  • CNC-machined exhaust tips – available in polished, black, or carbon fiber finishes to match the truck’s aesthetic.
  • Aircraft-grade hangers and clamps – resist corrosion and eliminate rattles over time.
  • 100% bolt-on design – uses factory mounting points for straightforward installation.

Borla backs its systems with a Million-Mile Warranty, which applies to the original purchaser and covers defects in materials or workmanship for the life of the vehicle. This warranty is transferable to subsequent owners for a fee, adding long-term value.

Choosing the Right Sound Profile

Before purchasing, it’s important to understand the three available sound levels because they affect both the driving experience and the perceived performance upgrade:

  • Borla Touring (409S) – The quietest option, designed for a deep, refined tone without drone at highway speeds. Best for daily drivers who want a mild improvement over stock.
  • Borla S-Type (403S) – A balanced sound with a noticeable growl under throttle while remaining civilized during cruising. The most popular choice for Ram 1500 owners.
  • Borla ATAK (404S) – The loudest and most aggressive, with a raw, race‑inspired exhaust note. Ideal for those who want maximum sound and are willing to accept some interior drone at low RPMs.

All three systems are claimed to deliver the same peak horsepower gain of 12 HP, though the S‑Type and ATAK may feel slightly more responsive due to reduced muffler absorption.

Cost Breakdown of the Borla Cat-Back Exhaust

The total investment for a Borla cat‑back system on a Ram 1500 typically falls between $1,000 and $1,600 for the hardware alone. Prices vary by series, truck cab configuration (crew cab, quad cab, regular cab), bed length, and whether the system includes a resonated or non‑resonated midpipe. Below is a realistic cost breakdown:

System Pricing (Retail)

  • Borla Touring (409S): $1,050–$1,250
  • Borla S-Type (403S): $1,100–$1,350
  • Borla ATAK (404S): $1,200–$1,600

These prices reflect the system only and do not include shipping or taxes. Many online retailers offer free shipping, and occasional sales can reduce costs by 5–15%. Be sure to confirm part compatibility with your specific Ram 1500 model year (2019–2024 5th‑gen trucks, for example, use different hanger placements than earlier generations).

Installation Costs

If you choose to have the system installed by a professional shop, expect to pay $100 to $300 in labor. The wide range depends on the shop’s hourly rate and whether any cutting or modification is needed (though Borla systems are designed to be bolt‑on, older trucks with rusted hardware can require extra labor). Some muffler shops will install customer‑supplied parts for a flat fee; others may charge by the hour (1–2 hours is typical).

DIY Installation Expenses

For the do‑it‑yourself route, additional costs may include:

  • Jack stands or ramps – $40–$100 (if not already owned)
  • PB Blaster or similar penetrating oil – $5–$10
  • Socket set and wrenches (metric and SAE) – already owned by many enthusiasts
  • Safety glasses and gloves – $10–$20
  • Torque wrench – $30–$80 (optional but recommended for proper clamp tightening)

Total DIY investment beyond the system: approximately $50–$200 if you need to purchase basic tools.

Installation Process: Step-by-Step Guide

Installing a Borla cat‑back exhaust on a Ram 1500 is a moderately easy job that can be completed in a home garage in about 1.5 to 3 hours. The process is the same for all three sound levels because the mounting points and pipe routing are identical. Below is a detailed installation walkthrough, including tips to avoid common pitfalls.

Preparation and Safety

  • Park on a level surface and allow the exhaust to cool completely if the truck has been driven.
  • Disconnect the negative battery terminal to prevent accidental sensor damage or electrical shorts.
  • Securely lift the rear of the truck using a pair of jack stands placed under the frame rails. Never rely solely on a jack.
  • Wear safety glasses and gloves – exhaust soot and rust can irritate skin and eyes.

Tools Required

  • 3/8” or 1/2” drive socket set with extensions (10mm, 13mm, 15mm, 18mm commonly used)
  • Combination wrenches (same sizes as sockets)
  • Penetrating oil (e.g., PB Blaster, Kroil)
  • Rubber mallet or dead‑blow hammer
  • Wire brush (for cleaning hanger rods)
  • Safety glasses and mechanic’s gloves
  • Torque wrench capable of 30–60 ft‑lb

Removing the Factory Exhaust

  1. Spray all exhaust hanger isolators and clamp bolts with penetrating oil. Allow 5–10 minutes to soak.
  2. Using a socket and wrench, loosen the two bolts connecting the factory exhaust to the catalytic converter flanges. These are often 15mm or 18mm.
  3. Remove the two rubber hanger isolators by sliding them off the metal hangers mounted to the frame. A rubber mallet or lubrication (soapy water) helps free them.
  4. Carefully lower the factory exhaust from the rubber mounts. The stock system is heavy – have a helper support it, or use a floor jack to lower it.
  5. Inspect the factory hanger rods for rust or damage. Clean them with a wire brush to ensure smooth reinstallation of the Borla hangers.
  6. Remove the stock exhaust tips if they are separate (some models have removable tips).

Installing the Borla Cat-Back System

  1. Begin by loosely assembling the Borla components on the ground: front pipe, muffler section, over‑axle pipe, and tailpipe with tip. Do not tighten any clamps yet.
  2. Slide the front pipe into the catalytic converter flange using the supplied gasket (if included). Hand‑tighten the flange bolts.
  3. Install the muffler section onto the front pipe. Ensure the hanger isolator aligns with the frame hanger rod. Use the supplied rubber isolator to attach it.
  4. Connect the over‑axle pipe to the muffler outlet, then the tailpipe section. Work from front to back, attaching each hanger as you go. Borla provides new rubber isolators; replace the factory ones for best results.
  5. Slide the clamp over each joint but do not tighten fully. This allows final adjustment of tip alignment and pipe clearance.
  6. Check clearances around the spare tire, shock absorbers, and brake lines. Rotate the pipes as needed to avoid contact.
  7. Align the exhaust tips so they are centered in the rear bumper cutouts and at the desired depth. Tighten all clamps to the manufacturer’s torque specification (typically 30–50 ft‑lb for 3‑inch clamps).
  8. Tighten the flange bolts to 35–45 ft‑lb (or as specified in the Borla instructions).
  9. Reconnect the negative battery terminal. Start the engine and listen for any exhaust leaks at the joints. Rev the engine gently and check for rattles or vibrations.
  10. If a leak is detected, inspect the clamp alignment and re‑tighten. Minor leaks sometimes seal after a few heat cycles.

Post-Installation Tips

  • After the first drive, re‑check all clamps – heat cycles can cause slight loosening.
  • If you experience drone at highway speeds, consider adding a resonated midpipe (available separately from Borla) or choose the Touring system for quieter operation.
  • Allow the system to “break in” for 500–1,000 miles – the sound will deepen and mellow slightly over time.

Performance Gains: The 12 HP Boost Explained

Borla’s advertised 12‑horsepower increase for the Ram 1500 is based on their in‑house dynamometer testing comparing the factory exhaust to the Borla system on a stock 5.7L HEMI V8. While 12 HP may not sound dramatic, it represents a roughly 3–4% improvement over the stock 395 HP rating. In real‑world driving, the gains manifest as improved throttle response and a stronger mid‑range pull, particularly between 2,500 and 4,500 RPM.

Dyno vs. Seat‑of‑the‑Pants

Many owners report that the “seat‑of‑the‑pants” feeling is more noticeable than the raw dyno numbers. This is because the Borla system reduces exhaust restriction, allowing the engine to rev more freely. Combined with a more aggressive sound, the subjective impression of speed can exceed the objective gain. It’s important to note that the 12 HP figure is for an otherwise stock engine; pairing the Borla exhaust with a cold‑air intake and a custom tune can yield cumulative gains of 25–35 HP.

Torque and Fuel Economy

In addition to horsepower, many drivers notice a slight improvement in low‑end torque, especially in the 1,800–2,800 RPM range where the HEMI produces peak torque. Better exhaust scavenging can also improve fuel economy by 1–2 MPG under steady cruising conditions, though aggressive throttle use tends to cancel out this benefit.

Sound Impact on Performance Perception

The louder exhaust note can make the truck feel faster because the engine sound is more present inside the cabin. This psychological effect should not be confused with actual acceleration increases, but it does enhance the driving enjoyment. For a more objective before‑and‑after comparison, consider recording 0–60 times or quarter‑mile passes using a GPS‑based timer.

Additional Considerations and Resources

Borla cat‑back exhaust systems are 50‑state legal because they replace components only after the catalytic converters. They do not affect emissions equipment and typically carry an Executive Order (EO) number confirming compliance with California Air Resources Board (CARB) rules. That said, some states have noise ordinances that restrict exhaust sound levels. The Borla ATAK system, in particular, may exceed local decibel limits. Check your state and local laws before purchasing.

Maintenance and Warranty

Stainless steel exhausts require minimal maintenance – occasional washing to remove road salt and grime will keep the finish looking new. The Borla Million‑Mile Warranty covers manufacturing defects but does not cover damage from accidents, abuse, or improper installation. Retain your original purchase receipt and register the system on Borla’s website to activate the warranty.

Where to Buy and Get More Information

For the most accurate pricing and fitment, visit the official Borla website or authorized dealers. The following external resources provide additional details:

Conclusion

The Borla cat‑back exhaust system is a high‑quality, bolt‑on upgrade that delivers a genuine 12 HP boost for Ram 1500 owners while transforming the truck’s character. With three distinct sound levels ranging from mild to wild, there’s an option for every preference, from daily commuters to off‑road adventurers. The installation is straightforward for a competent DIYer, and professional installation remains affordable. When combined with the Million‑Mile Warranty and durable stainless steel construction, a Borla exhaust represents a strong return on investment in terms of performance, sound, and resale value. Whether you choose the refined Touring, balanced S‑Type, or aggressive ATAK, you’ll enjoy a more engaging driving experience that makes every trip behind the wheel feel like an upgrade.