The exhaust is continually exposed to weather, salt, or other road filth since it is located below the vehicle. Because of the quick rust and subsequent increase in noise, you may get a penalty or become stuck. You should have the silencer mended as soon as possible to prevent it from totally sliding off, and the cost of doing so is shown below.
By 2023, the cost to weld in a new muffler will range from $70 to $150 for a single cut and weld, which translates to $140 to $300 if your vehicle has a front-to-back dual exhaust system. Depending on how rusty the metal is surrounding the leak, tiny leaks might cost you $30 to $100.
How many welders to Use for a Muffler Leak
There is no immediate need to replace the complete muffler if there is just a tiny hole that increases engine noise and no other major issues with the muffler. Take your vehicle to a muffler shop instead for an examination, and they will tell you immediately whether it is feasible to weld the leak shut; if it is, expect to pay between $30 and $70 for the repair.
You will be required to pay for one hour of work since fixing a muffler leak normally takes less than an hour, and this is what decides how much the whole service will cost. Muffler businesses now charge between $30 and $70 per hour, depending on where you reside and how well-known the shop is.
On the other hand, the muffler can be so rusty that the welder has to remove a section of its wall and install a new one. In such a situation, you would be better off purchasing a brand-new one since the price would have increased to around $100 to $150. But once again, it is something to address immediately with the welders.
A Muffler Leak Welding Cost
- Minor Leaks – $30 to $70
- Major Leaks – $100 to $150
How Much Weld Should Go Into a New Muffler
If the muffler is too damaged to repair, your only choice is to replace it. Nevertheless, doing so will result in a large increase in cost since we must add the muffler price to the welding cost. We will talk more about this later. You should expect to pay between $70 and $150 for one cut and one weld for welding costs.
The costs vary according to local hourly wages, the accessibility to the exhaust, and the general health of the exhaust system. In other words, if the exhaust system is rusty, it will cost more to fix since it will cost more to prepare, cut, and weld. The same applies if removing the exhaust requires extra effort, as it often does on high-end vehicles.
Also, the expenses will quadruple if your car has two exhaust pipes. And by “exhaust pipes,” we mean multiple exhaust pipes—not simply two exhaust tips—from the engine to the muffler. Due to the two cuts & two welds required for dual exhaust, the price has increased to between $140 and $300. A quad exhaust costs between $240 and $600.
Price of Welding in a New Muffler
- Single Exhaust Pipe – $70 to $150
- Dual Exhaust Pipes – $140 to $300
- Quad Exhaust Pipes – $280 to $600
Other Exhaust Sections Welding Cost
If your muffler has to be replaced because it has rusted out, there may be other rusty areas and leaks in the exhaust system that are only apparent when the vehicle is raised. Naturally, you also want to address them since an exhaust pipe leak will produce a lot more noise than a muffler leak.
Sadly, replacing an exhausted middle requires at least two cuts, costing at least $140. That adds additional components if the flex pipe, resonator, or flange is corroded. Regarding quad exhausts, it is uncommon for all four to be eroded, and since welding them would be costly, it is often more cost-effective to replace the complete cat-back or axle-back system.
Leak repairs will probably cost no more than $50 since, if possible, welding can be done considerably more quickly on a muffler. On the other hand, larger leaks are often repaired by installing the healthy Pipe we just mentioned.
Cost of Replacing and Welding an Exhaust Pipe Part
- One Pipe – $140 to $300
- Dual Pipes – $280 to $600
A mid-section exhaust leak’s fixed cost
- Minor leak – $30 to $50
New Muffler Prices
All the costs mentioned so far are simply for welding and do not include muffler costs. Mufflers are, unfortunately, not that inexpensive, and although you can buy used ones in decent shape, you will have to determine for yourself whether or not doing so is a wise idea. New muffler costs for tiny hatchbacks like the Honda Civic and Toyota Corolla start between $80 and $120. But remember that they are replacements, not original equipment, and muffler costs.
Going ahead, full-size truck muffler prices typically range from $150 to $250, and within that price range, there are several high-quality performance muffler alternatives. Mufflers on contemporary SUVs, such as the Ford Explorer, cost $200 to $300.
Lastly, luxury autos from Europe. Regarding BMW, Mercedes, Audi, Jaguar, etc., it is impossible to predict how much a new silencer will cost. It is because they often utilize far more intricate exterior and interior designs, and component supply may be constrained.
This implies you should not be shocked if a silencer costs more than $700 for larger versions. Muffler prices, however, are normally between $400 and $600 for vehicles like the smaller Audi A4, BMW 3-Series, and others.
Muffler Prices
- Small Hatchbacks – $80 to $120
- Full-Size Trucks – $150 to $250
- Mid Size SUVs – $200 to $300
- Premium Vehicles – $400 to $600
Which Welding Process Is Used for Exhaust?
The most common method of welding used for exhausts and mufflers is MIG welding, which is advantageous since it is the least expensive, simplest to learn, and quickest. Yet other automobiles have conventional stainless steel exhaust systems, which must be TIG welded.
Is Exhaust Difficult to Weld?
The kind of metal and the material’s condition both affect how difficult it is to weld an exhaust. For instance, even for inexperienced welders, welding a typical exhaust in excellent condition is pretty simple. But, even for seasoned welders, TIG welding a stainless steel exhaust may be difficult.
Is It a Good Idea to Weld an Exhaust?
Without a doubt, welding an exhaust is a wise decision. Welding is always a smart alternative, whether you want to repair an exhaust leak or replace a section of the exhaust. The exhaust manifold flanges, mufflers, catalytic converters, and other components are welded together.
Is It OK to Weld on a Car?
Sure, you can weld on a moving object, although turning off the batteries first would be wise. When the battery is attached, a short or voltage spike that travels through the vehicle ground and mostly destroys control modules and other electronics, including the batteries, may be caused by the welding machine.
Is Clamping or Welding the Exhaust Better?
Welding is by far the best in structural stiffness and sealing qualities compared to other options, including clamps. In addition to being one of the sturdiest metal connections currently in use, welding two metals together causes them to melt. Consequently, the connection is entirely sealed, exactly as it would be with a single piece of metal.
Can I drive if my muffler is broken?
You may drive with a damaged muffler if there is no risk of it coming off the car, which might endanger other motorists. Moreover, because a muffler makes an engine quieter, you may drive a vehicle without ever using one. But bear in mind that if the automobile is excessively loud, you may get a hefty punishment in several jurisdictions.
Can I Tape Over a Muffler Hole?
No, neither normal nor aluminum tape will work to patch a hole in a muffler. Manifold heat shield tape may be used even if not meant to halt leaks. As the heat shield tape is designed for thermal isolation, heat will not damage it, and once the heat is applied, it fuses, increasing the likelihood of a tight seal.
How Durable Are Mufflers?
Depending on where you reside, older mufflers with just paint as protection often survive between 3 and 6 years. Yet, current aluminized exhaust systems have a lifespan of five to ten years, but stainless steel mufflers have a lifespan of at least fifteen years.
Conclusion
We strongly advise you to study the whole text so you are aware of the rates that apply to you since the final cost of welding a muffler depends on various factors. But, the average cost of exhaust welding is $75, and you will wind up paying for an hour to patch little leaks. But, if you wish to change the silencer, each cut and weld will take 1.5 hours of effort.