Either the cost is "enormous" or "marginal". Make up your mind. All road signs have to be replaced from time to time. If you were really willing to convert to metric, you would have already put a plan into action decades ago to gradually convert those signs and by now you wouldn't have to repeat those paradoxical explanations that no one buys.
You've still missed the point:
What is the exact economic benefit of changing the units we measure our roads by from miles to km?
I understand that you believe that you can just start replacing signs as they wear out with km versions. Considering signs can and do last up to 30 years, this would take 30 years, during which time a certain percentage of the signs would be in KM and a certain percentage would be in miles. Oh, so maybe we replace with signs with both systems, then at some point where most of the signs have been replaced switch to 'only km' versions. That could take 50 years or more.
So the correct method is to replace big chunks all at once. Which is very costly. Let's just take speed limit signs. There are 4.2 million miles of roads in the US. I found a news article where a state changed their speed limit and replaced their speed limit signs at a cost of $134,000 for 810 miles of interstate. Let's just assume that's a good ratio. $134,000 for 810 miles. $165 per mile, multipled by 4.2 million miles, is just under 700 million dollars just for the speed limit signs. Then add in the much more expensive direction signs, distance signs, the mile markers along the road and on and on, and you are probably talking at least few billion dollars to just change the signage.
Not to mention all of the side effects of this change. If you look at news articles about Interstate 17 in Arizona, you'll find lots and lots of people not happy about it being changed (eventually) back to miles because of the costs of the side effects (changing exit numbers, directions, etc, on printed material, and other costs).
And again, for what economic benefit? Show us how we're going to save a few billion dollars by doing this and it will probably get done. But as it is now, most people don't see a good reason to change this particular thing. I get into my car, I look at the speedometer I make sure it doesn't exceed (by very much) the posted speed limit. The distance signs also need to be in the same units since I just take the distance to the destination and divide by the current speed. It doesn't matter what the number system is, as long as everything matches. The distance could be miles, or kilometers, or furlongs or kilosmoots, it wouldn't matter. I'm not doing engineering with those figures, and in this case there are a lot of costs to do the change, for no real benefit.
It's really frustrating to hear people say "the US isn't metric". No, the US is metric, all of our units are defined in ratio to the metric unit, and every day more and more of the places where traditional measurements have been used are being replaced by metric measurements. All to point at our highway system which doesn't really matter what units it's measured in.