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In order to have a robust exhaust system design a comprehensive durability analysis is required. This durability analysis should include thermal loads, engine vibration loading, and proving ground road loads. The dynamic performance evaluation in exhaust system development is a valuable tool to identify the best design alternative. The finite element analysis (FEA) applications in the design of automotive exhaust system have become an indispensable tool. Both the cost and cycle of the product development benefit from its usages. This paper presents a robust design procedure for the dynamic performance of exhaust system in a passenger vehicle. For dynamic analyses it is essential that the complete exhaust assembly is modeled, including manifold, a representation of the engine, and a flex decouple model. This is because dynamic excitation is predominantly comprised of unbalanced forces within the engine, which is transmitted to the exhaust system through the flex decoupling element.