Upgrading your Chevrolet Silverado's exhaust system to a Borla S-Type is one of the most rewarding modifications you can make. Not only does it unlock a deeper, more aggressive exhaust note, but it can also improve throttle response and add a few genuine horsepower and torque gains. This guide provides a detailed, professional walkthrough of the entire installation process, from removing the factory system to performing the final start-up checks. Whether you're a seasoned DIYer or tackling an exhaust swap for the first time, these steps will help you achieve a leak-free, properly aligned install that will deliver years of trouble-free service.

Understanding the Borla S-Type Exhaust

The Borla S-Type is a popular aftermarket exhaust system designed to provide a sporty, aggressive sound without the drone and harshness of a straight-through or race exhaust. It uses a patented multi-core technology that combines sound-absorbing materials with tuned resonator chambers to produce a refined tone that deepens under hard acceleration and quiets down during highway cruising. For Silverado owners, the S-Type delivers a noticeable boost in exhaust flow compared to the restrictive factory system, which can help the engine breathe more freely and potentially gain a few horsepower when paired with a performance tune.

The system typically includes a stainless steel muffler, mandrel-bent pipes, and polished exhaust tips. Borla uses aircraft-grade T-304 stainless steel, which resists corrosion far better than aluminized steel, making it a worthwhile investment for trucks in colder or coastal climates. Before starting, verify that your specific Silverado model and engine size are compatible with the Borla S-Type part number you purchased. Most systems are engineered for direct bolt-on installation, but having the correct part for your year, cab configuration, and wheelbase is essential.

Benefits of Installing the Borla S-Type

  • Enhanced Sound: A deep, aggressive exhaust note that is present but not overwhelming inside the cab.
  • Increased Performance: Reduced backpressure can lead to modest gains in horsepower and torque, especially when combined with an intake and tune.
  • Corrosion Resistance: T-304 stainless steel construction provides superior longevity.
  • Improved Exhaust Flow: Mandrel-bent tubing eliminates restrictions found in factory crush-bent pipes.
  • Easy Installation: Most kits use factory hanger locations and pre-welded flanges for a direct fit.
  • American Manufacturing: Borla systems are designed, engineered, and built in the USA with a million-mile warranty.

Tools and Materials You'll Need

Having the right tools on hand will make the job smoother. Here's a comprehensive list:

  • Borla S-Type exhaust system (check part number for your Silverado)
  • Floor jack and two sturdy jack stands (minimum 3-ton capacity recommended)
  • Socket set with metric and SAE sockets (½-inch drive recommended for stubborn bolts)
  • Combination wrench set
  • Exhaust hanger removal tool (or a long flathead screwdriver and pliers)
  • Penetrating lubricant (e.g., WD-40 Specialist, PB Blaster)
  • Safety glasses and mechanic's gloves
  • Torque wrench (for tightening clamps and bolts to spec)
  • Rubber mallet (for gentle persuasion on stuck hangers)
  • Shop rags or paper towels

Safety Precautions Before You Begin

Safety Tip: Never work under a vehicle supported only by a jack. Always use jack stands rated for the weight of your truck. If you have a driveshaft center support bearing or other components in the way, ensure they are not compromised during the job.

Park your Silverado on a flat, level surface and engage the parking brake. Chock the rear wheels to prevent movement. Allow the exhaust system to cool completely if the truck was recently driven. Hot exhaust components can cause serious burns. Wear safety glasses to protect your eyes from falling debris and rust flakes.

Step 1: Remove the Factory Exhaust

Raising the Truck and Gaining Access

Place the floor jack under the rear axle's differential or frame rail (check your owner's manual for proper lift points). Lift the truck enough to slide in jack stands under the frame at the designated points, typically behind the front wheels and ahead of the rear axle. Lower the jack carefully until the truck rests securely on the stands. Shake the vehicle gently to confirm stability before crawling underneath.

Spray All Fasteners with Penetrating Lubricant

Generously apply penetrating lubricant to all exhaust flange bolts, hanger rod nuts, and any rubber mounts you plan to remove. Let it soak for at least 10–15 minutes. This step is crucial for preventing rounded bolts and broken studs, which are common on older trucks with rust-prone hardware.

Unbolt the Exhaust from the Manifold and Catalytic Converter

Using a socket and ratchet, remove the bolts connecting the factory exhaust pipes to the exhaust manifolds. You'll also need to unbolt the mid-pipe or Y-pipe from the catalytic converter flanges. In many Silverado models, there are two flanges—one for each side of the engine. Keep these bolts and nuts; you may reuse them for the new system, though Borla often includes new hardware. If any bolts are seized, apply additional penetrating oil and use a breaker bar or impact wrench to break them free slowly.

Detach the Exhaust Hangers

Locate the rubber exhaust hangers that support the pipes along the frame. Use an exhaust hanger removal tool (or a flathead screwdriver and pliers) to pry the metal hanger rod out of the rubber isolator ring. Lubricant spray makes this easier. Work section by section, starting at the rear and moving forward. Have a helper support the heavy muffler section as you release the last hangers to prevent it from dropping onto you.

Remove the Old Exhaust in Sections

If the system is in multiple pieces, disconnect them at the slip joints (usually held with band clamps) and slide the sections out from under the truck. For a single-piece cat-back system, you may need to twist and maneuver the pipes to clear the rear axle. Be careful not to hit the fuel tank or brake lines. Once removed, set the old exhaust aside for recycling or disposal.

Step 2: Prepare the Borla S-Type System

Inspect and Lay Out Components

Open the Borla box carefully and remove all parts. You should find the main muffler assembly, intermediate pipes, tailpipe sections, exhaust tips, clamps, and hardware (bolts, nuts, washers). Compare the components to the instruction manual included with the kit. Some systems come partially assembled—do not fully tighten any clamps until the whole system is loosely hung to allow for adjustment.

Check Fitment and Orientation

Position the muffler and pipes along the underside of the truck, matching them to the factory routes. Notice that the muffler often has an inlet and outlet orientation; arrows or labels indicate the correct direction of exhaust flow. Confirm that the tailpipes will exit in the desired location (behind the rear wheel or straight out the back). For Silverado models with dual exhaust cutouts, ensure the tips clear the bumper and trim pieces.

Step 3: Install the New Exhaust System

Start with the Muffler

Lift the Borla muffler into position under the truck. Align its inlet flange with the pipe coming from the catalytic converter (or the mid-pipe if you have a cat-back system). Install the provided gasket (if applicable) and thread the bolts through the flanges. Tighten lightly with your hand until the muffler is snug but still able to pivot. This play will make connecting the rear pipes easier.

Attach the Intermediate and Tail Pipes

Slide the intermediate pipes or tailpipe sections onto the muffler's outlet. Use the supplied band clamps to connect them loosely. Each clamp should be finger-tight so the pipe can rotate and slide for fine-tuning alignment. Work your way rearward, joining each section with clamps. On Silverado models with long wheelbases, you may have an extension pipe that reaches the rear axle—ensure it clears the suspension and driveshaft.

Connect the Exhaust Tips

Once the tailpipe is in place, slide the polished tip onto the end. Borla tips are usually secured with a set screw or a small clamp. Position the tip so it is centered in the bumper opening and extends to your preferred depth (flush or slightly recessed). Tighten the set screw gently—do not overtighten, as it may mar the finish.

Step 4: Reattach Exhaust Hangers

Install Hangers in the Stock Locations

Snap the hanger rods (attached to the new pipes) back into the existing rubber mounts. Use the hanger removal tool or lubricant to push the rod through the isolator. If the new system uses different hanger positions, Borla includes adapters or instructions. Ensure every hanger is engaged securely. A loose hanger can cause rattles and put stress on flange bolts.

Adjust Pipe Clearance

With the system hanging loosely, check for proper clearance around the exhaust tunnel, frame rails, and rear axle. Rotate the pipes as needed to keep them from contacting the body, fuel lines, or brake cables. A minimum of 0.5 inches of clearance is recommended. If a pipe hits the frame when the suspension cycles, you may need to loosen clamps and reposition.

Step 5: Tighten All Fasteners and Final Checks

Torque Flange Bolts and Clamps

Inspect All Connections for Leaks

With the system secure, start the engine (in a well-ventilated area or outdoors) and let it idle. Listen for any hissing or ticking sounds near flanges and clamps. You can use a shop rag or glove to block the tailpipes and build backpressure momentarily, which may reveal small leaks. Alternatively, spray soapy water around joints and watch for bubbles. Tighten problem connections as needed.

Verify Exhaust Tip Alignment

Stand behind the truck and check that both tips (if dual) are level and symmetrical. Adjust by loosening the tailpipe clamps and rotating slightly. Re-tighten and re-check. Poorly aligned tips not only look sloppy but can also cause exhaust to blow against the bumper, leading to soot buildup and potential paint damage.

Step 6: Lower the Truck and Road Test

Lower Safely

Remove the jack stands one at a time and lower the truck carefully. Ensure nothing is caught under the wheels and that the exhaust system has not shifted during this process. Re-check hanger positions after the truck is back on the ground, as the suspension geometry changes.

Perform a Sound Check

Start the engine again after lowering. The Borla S-Type will settle into its characteristic tone after the system heats up and the titanium-based sound materials (if present) stabilize. Let the engine run for a few minutes, then rev it gently to hear the full range. Expect a deep, mellow idle that rises to an aggressive roar at higher RPMs — but should not drone excessively in the cab at cruising speeds.

Road Test and Re-Torque

Take the truck on a short drive, running through city streets and a stretch of highway. Listen for any rattles, clunks, or persistent drone at 1,500–2,000 RPM (common cruising range). After the drive, park on a level surface and re-inspect the exhaust system while it is hot. You may need to re-torque the clamps after the metal expands and contracts — this is normal. A final check under the truck for clearance and hanger engagement ensures long-term reliability.

Maintenance Tips for Your Borla Exhaust

  • Periodically check clamp tightness, especially after the first few thermal cycles.
  • Clean the polished tips with a dedicated stainless steel cleaner and a microfiber cloth to prevent oxidation.
  • Inspect hangers and rubber mounts during oil changes for signs of cracking or sagging.
  • If you live in salt-prone areas, consider applying a light coat of anti-seize to flange bolts annually.

External Resources

For further technical details, we recommend consulting Borla's official product page for your specific Silverado system, which includes installation videos and torque specs. The SilveradoSierra.com forum has many owner reviews and tips for tackling common rusty bolt issues. Additionally, this general exhaust installation guide covers basic principles applicable to any truck.

Conclusion

Installing a Borla S-Type exhaust on your Silverado is a weekend project that yields immediate auditory and performance rewards. By methodically removing the old system, preparing the new components, carefully aligning and securing the Borla unit, and performing thorough leak and sound checks, you can enjoy a professional-grade install. The S-Type's balanced tone and durable construction make it a standout choice for Silverado owners who want an aggressive upgrade without sacrificing daily drivability. Take your time, use the right tools, and enjoy the satisfying rumble of your truck's new voice.