aFe Intercooler BladeRunner EcoBoost 2.7L/3.5L F-150 2015-2016

100% of 100


  • Direct Fit Upgrade
  • Flows 20% Better Than OEM
  • 3" Bar And Plate Core Design
  • 2-1/2" Inlets And A 3" Outlet
MSRP $1,841.25
You save 20%

aFe BladeRunner Intercooler for 2015-2016 F150s with a 2.7L or 3.5L EcoBoost Engine.

The power added to your EcoBoost engine is only limited by how much cool air you can get to it under the harshest of driving conditions. That’s why aFe has introduced their BladeRunner Intercooler (46-20201), which is now available to purchase here at CJ Pony Parts!

The upgraded intercooler utilizes a 3” bar and plate core design that increases the OEM tube and fin core design by up to 20% while being 95% more efficient. How do you say no to this no-brainer of a mod for your 2015-2016 F150 with a 2.7L or 3.5L EcoBoost engine!

Features and Benefits:
- Direct Fit Upgrade That Mounts In the Factory Location
- Multi-Directional Vane Technology (MDV)
- Pressure Test Rated at 100 PSI
- Flows 20% Better Than OEM Intercooler
- 3" Bar and Plate Core Design
- Billet Aluminum 2-1/2" Inlets and a 3" Outlet
- Two 3/16" TIG-Welded End Tanks
- 1/8” NPT Brass Breather Vent Fitting
- CNC Machined Bypass Flange
- Condensation Drain
- Straight-Forward Installation
- Includes All Necessary Mounting Hardware

This BladeRunner Intercooler from aFe is manufactured with a 3” Bar and Plate Core design which offers strength and durability while incorporating two 3/16” TIG-Welded End Tanks. With aFe’s Multi-Directional Vane Technology, this intercooler is pressure rated up to 100 PSI. This intercooler also flows 20% better than your current factory intercooler and has billet aluminum 2-1/2” inlets and a 3” outlet.

This intercooler also utilizes a CNC machined bypass flange that allows the intercooler to be used on all 3.5L EcoBoost F150 models by either incorporating the factory Electronic Re-circulating Valve, or closing the port with the included block-off plate. The engineers at aFe also addressed the factory intercooler water condensation issue by incorporating a CNC machined vent tube which uses a brass 1/8" NPT breather vent. For those that choose to not use this feature, a solid NPT plug is also provided.

When tested at an ambient temperature of 70 degrees Fahrenheit, the BladeRunner cooled the outlet flow temperature to 77 degrees. Under the same conditions, the factory unit cooled the outlet flow temperature to a dismal 91 degrees. The installation for this intercooler from aFe uses all factory mounting locations for a simple, straight-forward installation!

*This part will not fit F-150 Raptor models.

Please Note: aFe's BladeRunner intercooler is legal in California only for racing vehicles that may never be used upon public roads.

Order this aFe (46-20201) BladeRunner Intercooler for your 2015-2016 F150 with a 2.7L or 3.5L EcoBoost Engine from CJ Pony Parts today!

California Residents: Proposition 65 Warning

Related Categories: Ford F-150 Parts, F-150 Engine, F-150 Intercoolers

Note: This item is not CARB (California Air Resource Board) exempt and is not legal for sale or use in the state of California.

Installation Videos

Video Transcript

A few months ago, we upgraded the twin turbos on our 2016 EcoBoost F-150, and now with the added power we need to keep the intake temperatures down, so today we're going to be installing this aFe BladeRunner intercooler. This intercooler features a three inch bar and plate design with multi-directional vein technology that'll float 20% better than the factory intercooler. It'll directly replace the factory intercooler and will work with factory or after-market piping. It's going to help to lower those intake temperatures to improve performance and keep it running safe, so today we're going to install it on our 2016 F-150.

For this installation, you'll need a lift or a jack and jack stands, seven millimeter socket, eight millimeter socket, 13 millimeter socket, 7/16 socket, 10 millimeter socket, six millimeter hex key, 3/8 ratchet, 1/4 inch ratchet, 13 millimeter wrench, and a panel removal tool.

The installation of this intercooler is pretty straight forward, but because we have this ADD bumper on, we actually need to remove it to gain access to it. If you have the factory bumper, you don't need to do anything with your bumper, but in our case this thing needs to come off. All right, now we have the bumper off. The first thing we're going to do is loosen up all the clamps that hold the pipes to the intercooler, and then we can drop down the plate to remove the intercooler. Now these are after-market pipes, so we're going to be using a 10 millimeter socket to get these clamps off, but the factory pipes use a flat-head screwdriver or a seven millimeter socket. Now we're going to remove both clamps. Now we're going to remove both couplers to the intercooler. Remove the retaining ring from the intercooler side, then separate the cold pipe from the intercooler. Then, if you have the factory blow-off valve you disconnect the hose here, but in our case we have a turbo smart blow-off valve, so we don't need to disconnect it.

There's two 13 millimeter bolts on each side right here, and one right here. Remove these so you can drop the plate and remove the intercooler. Here's a side-by-side comparison of the factory intercooler and the aFe BladeRunner. As you can see, the aFe’s an inch taller, and it has fully TIG-welded end caps. Next, we have to move the factory couplers over to the aFe intercooler. At this point, you can reinstall the factory blow-off valve or install an after-market one, as well. These EcoBoosts actually have a condensation issue inside the intercooler - they'll get a lot of moisture and oil buildup, and one way aFe is going to combat that issue is by installing a breather filter on the driver side of the intercooler and a plug on the passenger side.

Because the intercooler's taller than the factory one, we need to space the top intercooler supports. We need to remove the 13 millimeter bolt on each side and add the provided spacer. Install the provided spacer between the frame and the bracket and install the provided bolts. Then tighten the bolts with a six millimeter hex key. Then do the same thing on the other side. One more thing to do before putting the intercooler back in the truck is removing the rubber grommets and placing them on the aFe intercooler.

Once the intercooler is up, reinstall the two bolts on the bottom of the bracket. Once the intercooler is in place you can reinstall the hot pipes. With both pipes fully seated, we can tighten the clamps, then reconnect the bypass hose, then reconnect the cold side intercooler pipe. Install the retaining ring on the slots of the collar closest to the intercooler. All we have to do now is reinstall the bumper, which you probably won't have to do, so with that being said, our installation is finished.

Our aFe BladeRunner intercooler is installed. It's definitely going to help to keep our intake temperatures a lot lower. Fitting it was spot on, and installation wasn't too bad. It should take you about less than two hours, and before you know it you'll be heading off-road.

Vehicle Fitment

This product will fit the following F-150 years:

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