Introduction: Why Upgrade to a Borla Exhaust on Your Tundra?

Your Toyota Tundra is a capable full-size truck, but the factory exhaust system often leaves performance and sound on the table. Upgrading to a Borla exhaust system transforms your Tundra into a more powerful, aggressive, and efficient machine. Borla is a leading aftermarket exhaust manufacturer known for premium stainless steel construction, patented Aero-Turbine technology, and a distinctive deep tone that never drones. This comprehensive guide walks you through every phase of installing a Borla exhaust system—from selecting the right kit to final tuning—ensuring you get maximum return on your investment.

Installing a new exhaust yourself can save hundreds of dollars in labor and give you intimate knowledge of your truck’s undercarriage. However, success comes from proper preparation, the right tools, and careful attention to manufacturer specifications. This article covers everything you need to know, including torque values, hanger positioning, and post-installation diagnostics, to ensure your Borla exhaust performs flawlessly for years.

For reference, Borla offers several exhaust families for the Tundra, including Borla S-Type (a sportier, deeper tone), Borla ATAK (the loudest, most aggressive option), and Borla Touring (a refined, moderate sound). The installation process is similar across all models, but always check your specific kit’s instructions for any unique steps.

Benefits of a Borla Exhaust on Your Toyota Tundra

Before diving into the installation, it pays to understand exactly what you’re gaining by swapping the stock exhaust for a Borla system.

Increased Horsepower and Torque

Borla exhaust systems are engineered to reduce backpressure, allowing the engine to breathe more freely. The result is a noticeable gain in both horsepower and torque, especially in the mid-to-high RPM range where the Tundra’s 5.7L V8 (or 4.6L V8) performs best. Many Tundra owners report a seat-of-the-pants improvement in throttle response and towing power after installation.

Superior Sound Quality

Borla’s patented Aero-Turbine technology eliminates drone while delivering an aggressive, race-bred exhaust note. You get a deep, muscular growl under acceleration without the annoying highway drone that plagues many off-road exhausts. The sound is loud when you want it and civil when cruising.

Durability and Corrosion Resistance

All Borla exhaust systems are made from T-304 stainless steel, which is superior to the aluminized steel used in many factory and budget aftermarket systems. T-304 resists rust, corrosion, and heat-induced discoloration, making it ideal for trucks exposed to road salt, mud, and extreme temperatures. Borla backs their products with a Million-Mile Warranty, a testament to their confidence in durability.

Improved Fuel Economy (Marginal)

While not a primary goal, the reduced backpressure and improved exhaust scavenging can yield a 1–2% improvement in fuel economy under normal driving conditions. This is because the engine expends less energy pushing exhaust gases out, allowing more efficient combustion.

Enhanced Appearance

Borla exhausts feature mirror-polished or matte stainless steel tips that dramatically upgrade the rear look of your Tundra. Kits often include dual or single polished tips that align perfectly with the rear bumper cutouts, adding a custom touch without being over-the-top.

Tools and Materials Needed

Having every tool ready before you start prevents frustration and mid-job trips to the auto parts store. Gather these items:

  • Socket wrench set (metric, 10mm–19mm range)
  • Torque wrench (capable of 30–80 ft-lbs)
  • ½-inch breaker bar (for stubborn bolts)
  • Jack and two jack stands (minimum 3-ton capacity)
  • Rubber mallet (to loosen hanger connections)
  • Penetrating oil (like PB Blaster or WD-40)
  • Safety glasses
  • Mechanic’s gloves
  • New Borla exhaust system (complete cat-back kit)
  • Pipe cutters or reciprocating saw (only if removing a welded section)
  • Exhaust hanger removal tool or pliers
  • Shop rags and degreaser (for cleaning connection points)

Check that your Borla kit includes all necessary clamps, gaskets, and hardware. If any component is missing, contact Borla or your dealer before starting. Some kits may require a 3-inch to 2.5-inch reducer if your Tundra is an older model with a smaller factory pipe; confirm compatibility beforehand.

Preparation: Getting the Tundra Ready

Proper preparation ensures a safe, clean install. Follow these steps:

  1. Park on a level, solid surface. Concrete garage floors are ideal. Avoid gravel or dirt that can shift.
  2. Engage the parking brake and chock the rear wheels.
  3. Disconnect the battery negative terminal (this prevents accidental shorting and clears ECU adaptations for better learning after the install).
  4. Wear safety glasses and gloves at all times. Exhaust systems have sharp edges and carbon deposits.
  5. Lift the rear of the Tundra using a jack at the rear differential or designated rear frame lift points. Place jack stands under the frame rails just ahead of the rear axle. Lower the jack until the truck rests securely on the stands. Ensure the stands are rated for the weight.
  6. Spray all exhaust hanger bushings and flange bolts with penetrating oil. Let it soak for at least 10 minutes while you organize your tools. This dramatically simplifies removal of corroded components.

If your Tundra has significant rust (common in salt-belt trucks), consider applying extra penetrating oil and letting it soak overnight before tackling the job.

Removing the Factory Exhaust System

Removing the stock exhaust is the most labor-intensive part of the job. The factory system is typically a single piece from the catalytic converter back, with several rubber hangers and two flanges. Here’s how to proceed:

Step 1: Remove the Exhaust Hangers

Using a socket wrench with a 14mm or 12mm socket (depending on your Tundra model year), unbolt the two hanger brackets that attach the muffler and intermediate pipe to the frame. Some hangers use rubber bushings that slide off with a little prying; use an exhaust hanger removal tool or a flathead screwdriver to gently pry the bushing free. Be careful not to tear the rubber—though you won’t reuse them if you upgrade to Borla’s rubber mounts.

Step 2: Disconnect the Flange at the Catalytic Converter

The factory exhaust connects to the catalytic converter via a two-bolt flange (often 14mm or 15mm). Use a breaker bar and appropriate socket to break these bolts loose. They may be very tight due to heat and corrosion. If they strip or break, you’ll need to drill them out and replace with grade-8 bolts—avoid this by applying penetrating oil and using steady, careful force.

Step 3: Remove the Muffler and Tailpipe

Once the flanges and hangers are free, the entire cat-back section should be loose. Slide the pipe back toward the rear of the truck to separate it from the catalytic converter outlet. Lower the muffler and tailpipe assembly from the vehicle. If the system is rust-welded together (common in older trucks), you may need to cut the pipe near the rear axle with a reciprocating saw or pipe cutter. Always cut in a location where the new Borla system will cover, and avoid damaging the brake lines or fuel tank.

Step 4: Clean the Connection Points

Use a wire brush or sandpaper to clean the catalytic converter flange of any gasket residue, rust, or soot. A clean surface ensures a perfect seal with the new gasket. Also inspect the rubber hangers on the frame—replace any that are cracked or stretched with the Borla-supplied bushings.

Installing the Borla Exhaust System: Step-by-Step

Now comes the exciting part: bolting on your new performance exhaust. The order of assembly is critical to ensure proper alignment and clearance.

Step 1: Dry-Fit All Components

Before tightening anything, loosely assemble the entire Borla system from the catalytic converter back. Do not tighten clamps yet. Hang the muffler and tailpipe in their approximate positions. This allows you to adjust the system for optimal clearance around the spare tire, shock absorbers, and frame rails. Pay special attention to the tailpipe tips—they should sit evenly in the rear bumper cutouts, about ¼ inch from the bumper edge.

Step 2: Install the Intermediate Pipe (if applicable)

Many Borla cat-back kits for the Tundra include an intermediate pipe that replaces the factory pipe from the catalytic converter to the muffler. Slide the supplied gasket onto the studs of the catalytic converter flange, then attach the intermediate pipe using the new bolts (typically supplied with a blue thread locker). Hand-tighten the bolts.

Step 3: Mount the Muffler

Slide the muffler onto the intermediate pipe using the provided clamp. Position the muffler so that the inlet and outlet align with the rest of the system and the hanger brackets line up with the frame. Insert the rubber hanger bushings into the muffler brackets and push them onto the frame pins. Use a rubber mallet to gently tap them into place if needed.

Step 4: Attach the Tailpipe

Connect the tailpipe to the muffler outlet using another slip joint clamp. Ensure the tailpipe follows the factory routing—under the rear axle and up over the spare tire. Adjust the tip angle so it sits flush with the bumper. Most Borla tips are adjustable via a separate clamp. Once aligned, tighten the tip clamp hand-tight.

Step 5: Check Clearance and Angle

With everything loosely assembled, shake the exhaust to verify it doesn’t contact the undercarriage. Rotate the tailpipe as needed to maintain at least 1 inch of clearance from the spare tire, brake cables, and sway bar. If the tip hits the bumper, loosen the clamp and adjust the angle.

Step 6: Tighten All Connections to Spec

Now it’s time to make everything permanent. Using a torque wrench, tighten the flange bolts to the manufacturer’s specification (usually 35–40 ft-lbs for the catalytic converter flange). Tighten the slip joint clamps to 40–50 ft-lbs—do not overtighten as you can crush the pipe. For the hanger brackets, tighten to 15–20 ft-lbs. Recheck all connections.

Step 7: Reconnect the Battery and Start the Engine

Reattach the negative terminal of the battery. Start the engine and let it idle for a few minutes. Immediately check for exhaust leaks at every joint by feeling for puffs of air or listening for hissing sounds. If you hear a leak, shut off the engine and tighten the affected clamp further. Minor adjustments are normal.

Final Adjustments and Testing

A proper test drive is essential to confirm the exhaust is operating correctly and that you’ve eliminated any driveability issues.

Visual Inspection

With the engine running, visually check that the tailpipe tips are centered and that the exhaust isn’t vibrating against the bumper or frame. Have a helper rev the engine to 2,000–3,000 RPM while you watch for excessive movement.

Torque Re-check

After the first heat cycle, metal expands and can loosen clamp tension. Drive the truck for 15–20 minutes, then park it, let it cool slightly, and re-torque all clamps and flange bolts. This is a critical step many DIYers skip, but it prevents future rattles and leaks.

Listen for Drone or Rattle

The Borla system is designed to be drone-free, but improper installation can cause resonance. Drive on the highway at 65–75 mph with the windows up. If you hear a boomy drone, the muffler might be too close to the underbody or the tailpipe might be contacting the spare tire. Adjust as needed. A slight metallic rattle indicates a clearance issue—check the hangers and pipe routing.

Check Engine Light (CEL)

After installing a new exhaust, the ECU may need a few drive cycles to adapt. Rarely, a catalytic converter efficiency code (P0420) can appear if the downstream O2 sensor is reading differently due to altered exhaust flow. This is not harmful. If the CEL stays on after 50 miles, consider an O2 sensor spacer or tuning solution. For most Tundras, the Borla system does not trigger a CEL.

Performance Verification

Take the truck on a road with a mix of inclines and straightaways. You should notice quicker throttle response and a stronger pull from 2,500 RPM upward. The exhaust note should be deep and aggressive under acceleration, and quiet during cruising. If your Tundra feels sluggish, double-check that the exhaust isn’t restricting flow—a bent pipe or crushed gasket can cause backpressure.

Common Installation Mistakes and How to Avoid Them

  • Overtightening clamps: Too much torque can distort stainless steel pipes, causing leaks. Stick to the recommended ft-lbs.
  • Skipping the dry-fit: Installing one piece at a time without trial alignment often results in crooked tips or clearance issues. Always assemble loosely first.
  • Ignoring rusted bolts: If a flange bolt snaps, you face a more difficult repair. Penetrating oil and patience are your friends.
  • Forgetting to tighten after heat cycling: As mentioned, re-torquing after a short drive is essential for a seal that lasts.
  • Wrong gasket orientation: Some Borla gaskets are directional; ensure the raised ridge faces the exhaust flow.

Post-Installation Break-In Period

Like any high-performance exhaust, Borla systems require a break-in period of about 200–500 miles for the sound to fully develop. During this time, the exhaust packing material and metal will settle. The tone may become slightly deeper and louder. Avoid hard pulls or towing at max capacity until after break-in. After 500 miles, perform a final inspection of all clamps and hangers.

Maintenance Tips for Long Life

Your Borla exhaust is built to last, but a little care goes a long way:

  • Wash the tailpipe tips occasionally with stainless steel cleaner to remove road grime and prevent water spots.
  • Annually, inspect the exhaust system for loose clamps, corrosion at welds, or damage from road debris.
  • If you live in the rust belt, consider applying a high-temperature anti-seize compound to flange bolts before winter to prevent seizure.
  • Never use abrasive cleaners on polished tips; they can scratch the chrome-like finish.

Conclusion: Enjoy the Enhanced Driving Experience

Installing a Borla exhaust on your Toyota Tundra is one of the most rewarding upgrades you can perform. It improves power, adds an aggressive soundtrack, and gives your truck a custom, premium look. By following the steps in this guide—proper preparation, careful removal, precise alignment, and thorough testing—you ensure a professional-grade installation that will provide years of trouble-free enjoyment.

For additional technical specs, installation videos, and warranty information, visit Borla’s official website or consult a certified installer if you encounter complications: Borla Performance Industries and Toyota Tundra Official Site. You can also find model-specific discussions and tips from fellow Tundra enthusiasts on forums like Tundras.com and Toyota Nation Tundra Forum.

Remember, the first time you start your Tundra with the new Borla exhaust, you’ll know immediately that every minute spent under the truck was worth it. Happy driving!