The aFe 46-20108-B Bladerunner 3in Intercooler Tube Hot Side is a mandrel-bent 3-inch aluminum hot charge pipe featuring 5-ply couplings and an integrated 1/8-inch NPT sensor port.

The aFe Power BladeRunner 46-20108-B is a performance 3-inch passenger-side hot charge air cooler (CAC) intercooler tube and coupling kit engineered specifically for 2003–2007 Ford F-250, F-350, F-450, and F-550 Super Duty trucks and 2003–2005 Ford Excursions equipped with the 6.0L Powerstroke diesel engine. Precision-formed from 3-inch mandrel-bent lightweight aluminum tubing and finished in a durable, heat-insulating wrinkle-black powder coat, this hot charge pipe eliminates restrictive factory pipe bends to minimize pressure drops and maximize turbocharger flow efficiency into the intercooler. Featuring smooth radius transitions, bead-rolled retaining lips, and an integrated 1/8-inch NPT auxiliary port for boost gauges or water-methanol injection nozzles, it lowers exhaust gas temperatures (EGTs) while maintaining structural integrity under sustained high-boost pressures.

Restrictive factory pipe necks that choke hot-side airflow, boot blow-offs caused by weak retaining beads, high exhaust gas temperatures under heavy towing loads, heat-soak degradation, and lack of dedicated auxiliary sensor/injection ports are what this upgrade cures. On 6.0L Powerstroke applications, the passenger-side hot pipe endures the highest thermal stress in the entire charge-air system, receiving uncooled air straight from the turbo compressor discharge that can exceed 350°F. The factory hot pipe configuration creates unnecessary turbulence and restricts peak mass airflow when running upgraded turbochargers or aggressive performance tuning. The aFe BladeRunner 46-20108-B maximizes volume and heat dissipation with continuous 3-inch aluminum geometry that will never rust or deform under high clamp loads. It comes packaged as a complete installation kit containing the 3-inch mandrel-bent aluminum hot-side pipe, heavy-duty 5-ply reinforced silicone couplers, premium constant-tension stainless steel T-bolt clamps, and a threaded 1/8-inch NPT plug; cold-side CAC piping and aftermarket intercooler cores are sold separately.

It fits all 2003–2007 Ford Super Duty F-250, F-350, F-450, and F-550 trucks and 2003–2005 Ford Excursions equipped with the 6.0L Powerstroke turbo diesel engine (passenger-side hot charge pipe run; pairs with cold-side pipe kit 46-20109).

Fitment

• 2003–2007 Ford F-250 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-350 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-450 / F-550 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2005 Ford Excursion 6.0L Powerstroke Turbo Diesel
• Mandrel-bent 3-inch aluminum tubing provides maximum airflow and minimizes pressure loss
• Wrinkle-black powder-coated finish protects against corrosion and insulates from underhood heat
• Integrated 1/8-inch NPT port allows easy installation of a boost gauge sensor or injection nozzle
• Precision bead-rolled tube ends ensure a mechanical interlock that stops boot blow-off
• Includes heavy-duty 5-ply polyester-reinforced silicone boots engineered for high heat and boost
• Includes spring-loaded constant-tension stainless steel T-bolt clamps for uniform holding torque
• Direct factory mounting points maintain OE battery box and radiator hose clearances
• Backed by aFe Power’s 2-Year Limited Warranty

Park the truck on a level surface, set the emergency brake, and disconnect both negative battery cables. Allow the engine compartment and charge-air piping to cool completely before servicing. On the passenger side, loosen the factory T-bolt clamps at the turbocharger compressor outlet and at the lower intercooler inlet neck (accessible from beneath the front bumper or by pulling back the passenger-side wheel well splash shield) using an 11mm (or 7/16-inch) deep socket. Unbolt any factory mounting brackets securing the hot pipe to the engine block or alternator bracket, then maneuver the factory metal hot pipe and boots clear of the engine bay. Thoroughly clean the aluminum turbo compressor outlet neck and the lower intercooler inlet stub using brake cleaner and a lint-free cloth to eliminate all oil slick, soot, and road grit (any residual oil film left on the retaining beads will cause boots to slip under boost). If not using the integrated 1/8-inch NPT port, apply thread sealant to the included NPT plug and thread it securely into the port. Slide the provided 5-ply silicone couplers loosely onto each end of the aFe 46-20108-B aluminum tube along with the constant-tension T-bolt clamps. Lightly spray the inside of both couplers with isopropyl alcohol or aerosol hairspray to help them slide smoothly over the raised metal retaining beads. Lower the aFe 3-inch pipe into place, sliding the lower coupler onto the intercooler inlet neck and the upper coupler onto the turbo discharge outlet. Adjust the clocking of the pipe to maintain at least 1/2-inch radial clearance around the passenger-side battery tray, A/C lines, and upper radiator hose. Position each T-bolt clamp squarely behind the raised metal retaining beads on each pipe neck (never clamp directly on top of the bead). Using a calibrated torque wrench, tighten all four T-bolt clamp nuts to 9–12 ft-lbs (106–142 in-lbs) until the tension springs compress evenly. Reconnect both negative battery cables, start the engine, and perform a test drive bringing manifold boost pressure to 24–28 PSI under load to confirm zero charge-air whistling and complete boost retention.