Full-Race 2015-2023 Ford Raptor & F150 3.5L EcoBoost Intercooler Kit

A high performance intercooler is the most important upgrade for your turbocharged Ford EcoBoost engine.  Also known as the ‘C-A-C’ (Charge Air Cooler)  the intercooler's job is to cool the charge air temperatures and prevent knock.  The problem is OEM coolers can reach 190-220F at max load!  (this is way too hot). With only the Full-Race Intercooler upgrade installed, Inlet Air Temp (IAT) can drop 90+ degrees, controlling temps at or near ambient.

The Full-Race V2 Intercooler is the toughest and highest flowing intercooler ever developed for the Ford Raptor and EcoBoost F-150 trucks. Featuring aerodynamic cast end tanks with internal flow dividers, this hardcore intercooler supports a 1000cfm flow rate (that's a 70% increase of internal flow area over stock), and limits pressure drops to <1psi at 700+hp airflow rates.

Our solution uses efficient and durable bar-and-plate intercoolers with optimized Fin pitch, and expertly TIG welded endtanks in precise fixtures. This intercooler uses 3.0″ inlet / 3.0″ outlet and is available with water/meth bungs on the coldside charge pipe. Each intercooler is indivudally leak tested to 50psi, as even the tiniest hole can cause a dramatic loss in power.  Being that the stock EcoBoost intercooler mounting location is anything but ideal, Full-Race focused on making the installation of a steel bumper, bull bar, snowplow, and virtually any other form of F-150 front end upgrade fully compatible with this intercooler.
     
The 2015+ EcoBoost Ford F-150 (and its hardcore Gen 2/Gen 3 Raptor brethren) is the sort of truck that can tackle the worst forms of worksite abuse, and then shift gears to take on some serious off-road action over the weekend. Unfortunately, even the most hardcore trucks have their inherent pitfalls, with the intercooler portion of this pickup being one of its greatest weaknesses. 

Also known as the CAC (charge air cooler), the stock intercooler unit on the F-150 is tucked beneath the radiator, and sits toward the lower portion of the front grille. The OE EcoBoost intercooler is little more than an aluminum core that's been affixed to a couple of equally dinky plastic end tanks, which needless to say is not ideal for durability or for keeping intake air temperatures in check. Additionally, the stock intercooler does not allow the fitment of an aftermarket bumper (or a slew of other front-mount accessories), and will not support the addition of things like larger turbos or a tune on stock turbos. 
     
 

Simply put: The stock EcoBoost intercooler unit is not cool whatsoever, and its replacement should be a top priority when modifying an F-150 with a twin-turbo 3.5L EcoBoost engine.

Full-Race eliminates all of these issues via the use of an aerospace-grade intercooler core with TIG welded end tanks with internal flow dividers, and then gives it a hand-fabricated lower support beam constructed from high-strength steel for additional rigidity and longevity. Inlet and outlet sizing has been boosted to accommodate 3″ piping on each side, with the cold side of the charge pipe being fully customizable for those looking to slap in some water/meth injectors. Each intercooler can also be powder-coated black or gunmetal for additional appearance and protective purposes, with throttle body spacers for extra boost ports being optional as well. For those looking to get the most out of their EcoBoost engine, a Turbosmart Vee Port EM Valve or a Smart Port blow-off valve can be added to the mix. 

FULL-RACE FORD F-150 / RAPTOR ECOBOOST FRONT MOUNT INTERCOOLER KIT FEATURES

• High-efficiency core designed specifically for the 3.5L V6 EcoBoost engine
• CFD optimized high-strength cast end tanks using ANSYS software
• All necessary couplers, piping, and mounting bracketry
• Optional aluminum bungs on charge pipe to suit water/meth injection nozzles
• Retains OEM sensors and purge solenoid fittings, so no tuning is required
• Optional black or gunmetal powder coating
• Allows the use of off-road pre-runner bumpers, brush guards, and other front-mounted aftermarket upgrades
• Allows fitment of snowplow mounts and other work-related accessories

CUSTOMER FEEDBACK

SPECIFICATIONS

• Front mount intercooler core features a >1000cfm flow rate (70% increase over stock),
  
• Oversized 10mm charge air and 10mm ambient air paths (3.5mm larger than stock)
  
• Rated at having only a <1psi pressure drop at 700+hp airflow levels 
  
• 17.8L total internal volume
  
• Solid steel intercooler lower mounting beam
  
• Comes with intercooler upper mounting brackets
• Aluminum charge piping (for both hot and cold sides)
  
• Silicone couplers and metal clamps
  
• Horn relocation bracket
  
• Adaptive cruise control relocation bracket (if specified)
  
• Optional black powdercoating
  
• Turbosmart Vee Port EM Valve and Smart Port Valve BOV compatible

FITMENT

• 2015+ Ford F-150 Ecoboost 3.5L 
  
• 2017+ Gen 2 Raptor
  
• 2021+ Ford F-150 Ecoboost 3.5L 
  
• 2021+ Gen 3 Raptor (Factory Intercooler Fans Must Be Removed)
• Install Guide
• Install Video

Looking to ensure you get the perfect part for your unique application the first time? Full-Race is here to help.

Email us at gofaster@full-race.com or call us at (602) 437-2101 to find out how we can help you achieve your goals.

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