Real-World Transformation: Installing a $500 S&S Performance Exhaust on a Chevy Colorado

The Chevrolet Colorado occupies a sweet spot in the midsize truck segment: capable enough for weekend adventures yet comfortable for daily driving. Owners appreciate its balance of utility and ride quality, but many feel the factory exhaust system leaves performance on the table. After driving my Colorado for two years, I decided it was time to address that bottleneck. I ordered the S&S Performance Exhaust system, a cat-back setup priced at approximately $500, and installed it in my garage. What followed was a transformation that went beyond just sound — it altered how the truck delivered power, how it felt under throttle, and even how I approached my commute. Here’s the full account of that upgrade, including installation details, performance observations, fuel economy data, and a candid assessment of whether it’s worth the investment.

Why the Factory Exhaust Leaves Room for Improvement

Every production vehicle’s exhaust system is a series of compromises. Automakers must balance cost, noise regulations, emissions compliance, and manufacturing simplicity. The Colorado’s stock exhaust is no exception. It uses relatively narrow tubing, multiple restrictive bends, and a muffler designed primarily to suppress sound rather than optimize flow. This design creates backpressure that can hinder the engine’s ability to expel exhaust gases efficiently. When an engine struggles to push out spent gases, it cannot draw in the fresh air-fuel mixture as effectively, which directly reduces power output.

Aftermarket performance exhaust systems like the S&S unit address these compromises by using mandrel-bent tubing, larger diameters, and freer-flowing mufflers. Mandrel bending preserves the inner diameter at every curve, unlike crush bending which creates pinch points. The result is a smoother path for exhaust gases, reduced backpressure, and a measurable increase in volumetric efficiency. For the Colorado’s 3.6L V6 or the available Duramax diesel, even modest improvements in exhaust flow can translate into real-world gains in throttle response and mid-range torque.

Before committing to the purchase, I researched several options including systems from MagnaFlow, Borla, and Flowmaster. The S&S Performance system stood out because of its price point, the quality of its TIG welds, and overwhelmingly positive feedback from Colorado owners on forums. If you want to dig deeper into the theory behind exhaust scavenging and how it affects power delivery, this comprehensive article on exhaust scavenging from Engine Builder Magazine explains the principles in excellent detail.

Key Benefits of Upgrading

  • Reduced backpressure: Freer-flowing exhaust paths allow the engine to operate with less restriction, improving volumetric efficiency.
  • Weight reduction: Many aftermarket systems use lighter materials like aluminized steel or stainless steel, shedding pounds from the vehicle’s total weight.
  • Heat management: Better exhaust flow can help lower under-hood temperatures by moving hot gases away from the engine bay more quickly.
  • Acoustic tuning: A well-designed system produces a purposeful sound that enhances the driving experience without being obtrusive at cruising speeds.

Installation: A Weekend Job with Accessible Tools

I tackled the installation in my driveway over a Saturday morning. The process is well within the capabilities of a DIYer with basic mechanical experience, though a second pair of hands helps when aligning the tailpipe section.

Tools and Materials Required

  • Jack and two jack stands (or a set of ramps)
  • WD-40 or penetrating oil (for seized fasteners)
  • 13mm, 15mm, and 18mm sockets with ratchet and extensions
  • Torque wrench capable of reading up to 60 ft-lbs
  • Angle grinder or reciprocating saw (only if you need to cut the stock system)
  • Safety glasses and gloves
  • Exhaust hanger removal tool (or large pliers)

Step-by-Step Process

I started by lifting the rear of the truck with a jack and placing jack stands under the frame rails. Working on a level surface is critical because exhaust components must align properly to avoid rattles. I sprayed penetrating oil on all the bolts connecting the stock exhaust to the catalytic converter and on the rubber hanger isolators to make removal easier.

With the underside accessible, I unbolted the factory system at the flange behind the catalytic converter. The stock exhaust came off in two sections: the mid-pipe with the muffler and the tailpipe assembly. I carefully worked each hanger free using the removal tool. On my Colorado, the rubber isolators were stiff but manageable; a generous application of silicone spray lubricant helped them slide off the metal hangers without tearing.

Before installing the new system, I compared the S&S Performance exhaust against the stock parts. The difference in tubing diameter was immediately visible: the S&S pipes measured roughly 3 inches compared to the factory 2.5 inches. The mandrel bends were smooth and uniform, and the stainless steel construction felt substantially more rigid than the stock aluminized steel.

Installation proceeded in reverse order. I loosely fitted the mid-pipe section onto the hangers, then attached the muffler and tailpipe. Leaving all clamps hand-tight allowed me to adjust the positioning so the exhaust tips sat evenly within the bumper cutout. Once I was satisfied with alignment, I torqued all clamps to 35 ft-lbs and tightened the flange bolts to 40 ft-lbs. The entire job took about 2.5 hours, including cleanup and a final inspection for clearance around the spare tire and rear suspension components.

One tip: If you live in a region where road salt is used, consider applying anti-seize compound to the flange bolts and clamp threads. This will make future removal significantly easier. For a reference on proper exhaust installation techniques, this Motor1 guide to cat-back exhaust installation covers the general best practices for ensuring leak-free connections.

Measured Performance Gains: More Than Subjective Impressions

After confirming there were no exhaust leaks, I took the Colorado for a series of test drives. I wanted to gather both subjective impressions and, where possible, objective data.

Throttle Response and Power Delivery

The most immediate change was throttle response. The factory calibration felt slightly muted off-idle, as if the engine was hesitating before the torque curve built. With the S&S exhaust installed, that hesitation vanished. Tapping the accelerator produced an instantaneous rev increase, and the engine pulled more eagerly from 1,500 rpm onward. During highway merging from on-ramps, the truck accelerated with noticeably more authority. Passing maneuvers at 60 mph required less throttle input to achieve the desired acceleration, which made highway driving feel more relaxed.

I attribute this improvement to the reduction in backpressure, which allows the engine to operate more efficiently across its power band. The Colorado’s V6 benefits particularly in the mid-range, between 2,500 and 4,500 rpm, where daily driving most often occurs. While I did not have access to a chassis dynamometer, the seat-of-the-pants impression is that peak torque feels as though it arrives earlier and pulls harder through the mid-range.

Sound Quality and Cabin Experience

The S&S Performance system produces a deep, authoritative tone that broadcasts the engine’s character without crossing into obnoxious territory. At idle, the exhaust has a subdued rumble that communicates readiness. Under light throttle, the sound remains civilized, making conversational cabin volume fine. When accelerating aggressively, the note opens into a rich growl that lets you know the engine is working. There is no drone at cruising speeds on the highway — I measured interior noise levels at 70 mph using a decibel meter app, and the reading was only 2 dB above the stock exhaust. That difference is barely perceptible to the human ear.

This is a critical point because many aftermarket exhausts for midsize trucks suffer from resonance issues that make long drives fatiguing. The S&S engineers clearly tuned the muffler and resonator to eliminate those problematic frequencies.

Driving Dynamics and Confidence

Beyond raw power, the exhaust upgrade changed how the truck felt in traffic. The sharper throttle response made it easier to execute quick lane changes and merge into gaps. The improved exhaust note also provided better auditory feedback, allowing me to modulate the throttle more precisely. When towing a small utility trailer loaded with about 1,500 pounds of landscaping materials, I noticed the engine maintained speed on uphill grades with less throttle input than before. The exhaust system did not increase towing capacity, but it did make the powertrain feel more capable under load.

For anyone considering this upgrade for towing or off-road applications, the S&S system’s stainless steel construction resists corrosion far better than the factory aluminized steel. This is especially valuable if you frequently drive on unpaved roads or in wet conditions.

Fuel Efficiency: Real-World Data Across Driving Conditions

Fuel economy is a common point of debate when discussing performance exhausts. The theory is that reduced backpressure improves engine efficiency, which should translate to better mileage. However, the human factor — enjoying the new sound and driving more aggressively — often offsets any mechanical gains.

I tracked fuel consumption for three weeks before the installation and for four weeks afterward, covering similar routes and driving habits. My commute includes approximately 60% highway and 40% city streets.

  • Before installation: Average of 19.8 mpg combined, with highway trips averaging 23.1 mpg.
  • After installation: Average of 20.6 mpg combined, with highway trips averaging 24.3 mpg.
  • Best observed tank: 25.7 mpg on a 200-mile highway trip with cruise control set at 65 mph.

That represents roughly a 4% improvement in combined driving and a 5% improvement on the highway. While not a dramatic change, the efficiency gain is genuine and consistent with what other Colorado owners have reported. It is also worth noting that I deliberately avoided driving more aggressively after the installation to see what the system could deliver under normal operation. After the testing period, I allowed myself to enjoy the sound more freely, and fuel economy predictably dropped closer to the original baseline. The takeaway is that the exhaust system will not magically save you money at the pump, but it provides a measurable efficiency improvement if you maintain conservative driving habits.

For a deeper look at how exhaust modifications affect fuel economy, the EPA’s fuel economy technology page offers authoritative technical information about the relationship between engine breathing and efficiency.

Long-Term Impressions After 6,000 Miles

Having driven over 6,000 miles with the S&S Performance Exhaust, I can offer some durable impressions that go beyond the initial honeymoon period.

Build Quality and Fitment

The system has held up exceptionally well. The stainless steel shows no signs of surface rust or pitting, even after exposure to road salt during winter months. All welds remain intact, and the hanger isolators have not sagged or cracked. The clamps have maintained their torque, and I have not experienced any exhaust leaks at the joints. Fitment around the spare tire mount remains perfect, with no rattling or contact against the chassis.

Sound Evolution

Over time, the exhaust note mellowed slightly as carbon deposits formed inside the muffler and pipes. The initial aggressive edge softened into a more refined tone without losing the character that makes the upgrade worthwhile. Cold starts are noticeably louder than stock, but the system quiets down as the engine reaches operating temperature. This is typical of performance exhausts and should be expected.

Driving Habits and Deliverability

I have found myself driving differently with the new exhaust. The improved throttle response and auditory feedback make the driving experience more engaging, which has encouraged me to take longer routes on weekends just for the pleasure of driving. The system has also proven itself during a 500-mile road trip loaded with camping gear and two passengers. The truck maintained comfortable highway speeds on steep grades, and the cabin remained quiet enough for conversation and music.

Cost vs. Value: A Balanced Assessment

At approximately $500, the S&S Performance Exhaust occupies the mid-range of the cat-back market. Cheaper systems exist, often made from lighter-gauge materials or with simpler muffler designs, but they frequently suffer from drone issues or poor fitment. Premium systems from brands like Borla or Corsa can cost twice as much and offer incremental improvements in sound tuning or weight reduction.

For the Colorado owner who wants a meaningful upgrade without overspending, the S&S system delivers excellent value. You get:

  • + 4-5% improvement in fuel economy under normal driving
  • + Noticeably sharper throttle response and mid-range torque
  • + A well-tuned exhaust note that enhances the driving experience
  • + Stainless steel construction that will outlast the factory system
  • + Straightforward installation that can be done in a weekend

If you are chasing maximum horsepower gains from a naturally aspirated V6, a cat-back exhaust alone will not transform your truck into a race vehicle. You would need to combine it with a cold air intake, a custom tune, and perhaps headers to see larger gains. However, as a single modification, the exhaust provides the most noticeable return on investment in terms of driving feel and daily enjoyment.

A Community Perspective

Colorado owners are an active bunch, and forums are full of exhaust discussions. A quick look at the Colorado Fans forum reveals hundreds of threads comparing systems, sharing installation tips, and debating sound clips. The consensus among members who have installed the S&S system mirrors my experience: it offers a balanced improvement in sound and performance without the drone that plagues some competing products. Many owners also report that pairing the exhaust with a cold air intake yields a more pronounced power gain, as the engine can breathe freely on both ends.

Final Verdict

Upgrading to the S&S Performance Exhaust on my Chevy Colorado was a decision I have not regretted. The installation was manageable, the fitment was precise, and the results exceeded my expectations. The truck accelerates more eagerly, sounds purposeful without being intrusive, and even returns slightly better fuel economy when driven responsibly. For $500, that is a substantial improvement in the ownership experience.

If you are considering a similar upgrade, I recommend researching your specific engine and drivetrain configuration, as results can vary between the V6 and diesel models. Take the time to listen to sound clips from other owners, and do not hesitate to ask questions in community forums. A performance exhaust is one of those modifications that transforms how you connect with your vehicle, and the S&S system delivers that transformation at a price point that makes sense for most budgets. Whether you use your Colorado as a daily driver, a weekend toy, or a tow vehicle, this upgrade is worth serious consideration.