Intercooler Upgrade Kit

The PRL Motorsports Intercooler Upgrade Kit is engineered to provide consistent cooling performance for the 2015–2020 Ford F-150 2.7L and 3.5L EcoBoost. Designed as a direct-fit replacement for the restrictive OEM unit, this intercooler features a high-capacity bar-and-plate core paired with TIG-welded cast aluminum end tanks for maximum thermal efficiency and durability. Its heavy-duty construction offers improved impact resistance over the factory tube-and-fin intercooler, making it better suited for real-world driving, including towing and heavy load conditions. This intercooler has demonstrated significant performance improvements, with PRL's testing showing gains of +21.33 horsepower and +34 lb-ft of torque at 6300 RPM over the stock intercooler. It also shows improved heat soak resistance, retaining more power during consecutive pulls. In real-world towing tests with a 5600 lb trailer, it reduced charge air temps by 26.5°F during a hill climb and maintained a 20°F advantage over stock at the end. When combined with the PRL High Volume Intake System, gains can peak at +50 horsepower and +40 lb-ft of torque. Key features include a high-efficiency bar-and-plate core with optimized fin density, cast and machined aluminum end tanks, and TIG-welded construction for long-term durability. The kit includes an NPT drain plug for condensation build-up resistance and installs using factory mounting points and hardware with no trimming or modifications required. The kit comes with a 5-Layer Reinforced Silicone Coupler (2015–2020 specific) and 304 Stainless Steel Clamps. Fitments include the 2015–2025 Ford F-150 2.7L EcoBoost, 2015–2020 Ford F-150 3.5L EcoBoost, and 2017–2020 Ford F-150 Raptor. The product is subject to a Prop 65 warning regarding chemical exposure. Additionally, while PRL plans submission for CARB testing, it is noted as "NOT LEGAL FOR SALE OR USE IN CALIFORNIA ON ANY EMISSION CONTROLLED MOTOR VEHICLE" due to the lack of CARB EO submission for this specific part.