The aFe Power BladeRunner GT Series 46-20102-1 is an extreme-duty performance charge air cooler (CAC) intercooler system complete with matching 3-inch hot-side and cold-side charge pipes, 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. Centered around an oversized 3.15-inch bar-and-plate aluminum core, this intercooler features 3/16-inch thick TIG-welded sheet aluminum end tanks, heavy-duty 3.50-inch CNC billet aluminum inlet and outlet ports, and a test pressure rating of 200 PSI. To maximize complete charge-air flow velocity, the system includes mandrel-bent 3-inch aluminum hot- and cold-side boost tubes finished in a durable wrinkle-black powder coat, heavy-duty 5-ply reinforced silicone couplers, and spring-loaded stainless steel constant-tension T-bolt clamps.

Catastrophic OEM end tank crimp seam blowouts, cracked factory plastic driver-side cold pipes, boost leaks past degraded tank O-ring seals, elevated exhaust gas temperatures (EGTs) under heavy gross vehicle weight towing, heat-soak performance fade, and severe manifold pressure loss under aggressive tuning are what this complete package cures. Factory 6.0L cooling systems rely on thin tube-and-fin cores and plastic charge tubes that weaken under heat cycling and crankcase oil saturation. The aFe BladeRunner GT Series replaces every component from the turbo discharge to the intake manifold with oversized, race-proven aluminum hardware. Built-in 1/8-inch NPT auxiliary ports on the piping and end tanks allow easy integration of boost gauges, temperature probes, or water-methanol injection, while a lower 1/8-inch NPT condensation drain port with brass breather vent prevents moisture accumulation inside the core. It comes packaged as a complete system including the 3.15-inch bar-and-plate intercooler, 3-inch hot-side pipe, 3-inch cold-side pipe, 5-ply silicone boots, stainless T-bolt clamps, brass condensation breather, and NPT plugs.

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 (Note: Hot-side pipe requires single-alternator configuration; not legal for sale or street use in California under CARB regulations).

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
• Heavy-duty 3.15-inch bar-and-plate core design significantly outflows factory intercooler
• End tanks constructed from 3/16-inch thick aluminum plate, 100% TIG-welded for extreme durability
• Massive 3.50-inch CNC billet aluminum inlet and outlet necks withstand 200 PSI test pressure
• Includes 3-inch mandrel-bent aluminum hot-side and cold-side pipes in wrinkle-black powder coat
• Features pre-tapped 1/8-inch NPT auxiliary ports for sensors, gauges, or water-meth injection
• Includes lower 1/8-inch NPT brass breather vent to drain accumulated condensation
• Includes heavy-duty 5-ply reinforced silicone couplers and spring-loaded stainless T-bolt clamps
• Direct drop-in installation utilizing OEM core support mounting points and rubber isolators
• Backed by aFe Power's 2-Year Limited Warranty

Park the truck on a level surface, engage the parking brake, and disconnect both negative battery cables. Allow the engine bay and cooling system to cool down completely before disassembly. Remove the front grille assembly, upper radiator core support cover, and headlight bezels as needed to access the front cooling stack. Disconnect the hot-side and cold-side factory charge pipes and boots using an 11mm (or 7/16-inch) deep socket, removing the stock pipes from the vehicle. Unbolt the upper core support crossmember and upper intercooler mounting brackets, gently tilting secondary coolers forward without stressing sealed refrigerant lines. Lift the factory intercooler straight up out of the lower chassis rubber isolator perches. Inspect the lower rubber mounting grommets; clean them thoroughly or replace if dry-rotted. Install the included 1/8-inch NPT brass breather drain vent (or solid plug) into the bottom drain port of the aFe intercooler using thread sealant. Transfer the upper rubber mounting grommets to the aFe BladeRunner brackets. Lower the GT intercooler into the chassis perches, confirming the bottom pins seat squarely into the lower rubber isolators. Reinstall the upper core support crossmember and torque the upper intercooler retaining bolts to 18 ft-lbs (24 Nm). Pre-assemble the 5-ply silicone couplers and constant-tension T-bolt clamps loosely onto the new 3-inch hot-side and cold-side aluminum pipes. Lightly mist the inner lips of the couplers with isopropyl alcohol to slide them over the bead-rolled pipe ends and billet 3.50-inch intercooler necks. Position the hot-side pipe between the turbo outlet and passenger intercooler neck, and the cold-side pipe between the driver intercooler neck and intake elbow, ensuring 1/2-inch radial clearance around battery trays, radiator hoses, and steering shafts. Position every T-bolt clamp squarely behind the raised bead-rolled lips and torque all clamp nuts to 9–12 ft-lbs (106–142 in-lbs). Reassemble the front grille and trim panels, reconnect the battery cables, and perform a test drive under load bringing manifold boost pressure to 24–28 PSI to verify complete boost retention.