Intercooler Bar-and-Plate Cast Aluminum End Tanks

The PRL Motorsports Intercooler for the 2021–2025 Ford F-150 2.7L and 3.5L EcoBoost is engineered to provide consistent charge air cooling under demanding conditions like towing and heavy loads. It serves as a direct-fit upgrade, replacing the restrictive factory intercooler with a high-efficiency bar-and-plate core and durable, TIG-welded cast aluminum end tanks. This intercooler is built for enhanced durability and performance. Its heavy-duty construction is more resistant to impact than the stock tube-and-fin design. The unit is finished with a powder coat for superior corrosion resistance and longevity. Key features include a bar-and-plate core with optimized fin density, cast and machined aluminum end tanks, and TIG-welded construction. It also includes an NPT drain plug for condensation management and utilizes factory mounting points for a straightforward installation with no trimming required. In performance testing, the PRL intercooler alone demonstrated gains of +21.33 horsepower and +34 lb-ft of torque at 6300 RPM over the stock unit. Heat soak tests showed it retained significantly more power during consecutive pulls. Real-world towing tests with a 5600 lb trailer revealed a reduction of 26.5°F in charge air temperatures at the start of a hill climb, maintaining a 20°F advantage by the end. When combined with the PRL High Volume Intake System, peak gains of +50 horsepower and +40 lb-ft of torque were observed. Fitment is confirmed for the 2021–2025 Ford F-150 3.5L EcoBoost and 2021–2025 Ford F-150 Raptor models. The intercooler retains OEM shutters, bypass valve, and Raptor-specific fans. It includes a cold-side silicone coupler and stainless steel hose clamps. Please note: This part is not legal for sale or use in California on any emission-controlled motor vehicle, as testing and CARB EO submission are not yet complete.