-20%
Click to zoom in
BladeRunner charge piping for the exact engine
The aFe 46-20109 is the single cold-side charge pipe from intercooler to intake manifold for the listed Ford 6.0L turbo-diesel Power Stroke applications. It is aluminum charge piping, not a stainless-steel intercooler core or a complete cooling system.
Key Features
- Exact cold charge routing for the listed 6.0L Power Stroke; not gasoline, 7.3L, 6.4L or 6.7L coverage.
- Current primary descriptions specify five-ply silicone couplings and stainless-steel spring-loaded T-bolt clamps.
- The hot-side primary page reports up to 7% greater flow over its stock counterpart. The hot-side percentage is not a cold-pipe performance result.
- Accessory 1/8 NPT ports do not include new sensors or a water/methanol system. Generic Filter Included page fields do not add an air filter.
Fitment
| Years | Model | Exact engine / requirements |
|---|---|---|
| 2003β2007 | Ford F-250 / F-350 Super Duty | 6.0L turbo-diesel Power Stroke V8; exact manufacturer application |
| 2004β2005 | Ford Excursion | 6.0L turbo-diesel only; exact retailer model/engine coverage, not every named-trim certification |
| 2004β2007 | Ford F-450 / F-550 Super Duty | 6.0L turbo-diesel only; exact retailer scope, confirm actual chassis and connections |
| 2003 | F-450 / F-550 β unresolved | Conflicting retailer year scopes; not included as verified coverage pending exact chassis proof |
46-20109: Manufacturer instructions explicitly name F-250/F-350 2003β2007 with the 6.0L Power Stroke. Exact engine-specific retailer tables additionally name Excursion 2004β2005 and F-450/F-550 2004β2007. That additional detail is retailer evidence, not a manufacturer-explicit full trim/chassis table. Named Excursion trims still require the actual 6.0L diesel and connection/clearance checks. The standalone October 2012 cold manual lists four 3.5-inch T-bolt clamps and no plug. The February 2017 cold page linked under the combo lists four 3.25-inch clamps, one plug, possible fan-shroud trimming and a 100β200-mile recheck. Confirm actual supplied revision, clamp fit and sealing. Retailers conflict on 2003 F-450/F-550 coverage; that year is withheld pending exact chassis proof, not declared physically incompatible.
Specifications
| Detail | Value |
|---|---|
| Manufacturer Part Number | 46-20109 |
| Configuration | Charge piping and exact listed installation components; no intercooler core |
| Tubing / flow path | One nominal 3-inch cold tube; the opposite side and intercooler core are separate. |
| Finish | TIG-welded aluminum with wrinkle-black powder coating; stainless steel describes the clamps, not the tubes. |
| Clamps / fastening | The standalone manual says tighten until the clamp spring is compressed, without numerical torque or a mileage interval. A later combo cold-page revision adds 100β200 miles and possible fan-shroud trimming; confirm the applicable revision. |
| Original sensors / seals | The cold procedure temporarily removes the original intake filter/tubing and disconnects its sensors and coolant-overflow tube, then restores all original components and both battery connections. No new sensors are supplied. Cold hump-coupling directions differ from the hot coupling instruction. |
| Emissions | The current primary pages and linked manuals state these products are not CARB exempt and are unavailable for purchase in California or use on vehicles registered with the California DMV. |
What's Included
- One nominal 3-inch aluminum cold tube and two hump couplings.
- Four T-bolt clamps. The exact standalone manual labels them 3.5 inches; the later combined-kit cold page labels its four clamps 3.25 inches. Confirm the actual supplied revision.
- A plug is not listed in the standalone manual, although the current page describes an accessory port and the later combo cold page includes a plug. Confirm actual packing and proper unused-port sealing rather than promising a plug in every box.
- No hot tube, intercooler core, air filter, sensor or injection system.
About aFe Power
aFe Power develops application-specific intake, filtration, exhaust, cooling, tuning, suspension, drivetrain, and truck-performance components supported by product testing and documented installation requirements.
Related Parts
- Browse aFe Power by exact engine and charge-pipe configuration; the hot-only and hot/cold kits have different contents.
- Match actual inlet, turbo and intercooler connections. A shared engine size does not approve another model or year.
Frequently Asked Questions
What is the 46-20109?An engine- and year-specific BladeRunner charge-pipe kit, not a complete intercooler, turbocharger or air intake.
How many tubes and which side does this kit include?is the single cold-side charge pipe from intercooler to intake manifold for the listed Ford 6.0L turbo-diesel Power Stroke applications. It is aluminum charge piping, not a stainless-steel intercooler core or a complete cooling system.
Are the airflow claims guaranteed horsepower gains?No. The manufacturer reports side-specific flow comparisons; actual engine power, charge temperature and boost depend on the complete setup.
Which original couplings, vent or sensor components are retained?The cold procedure temporarily removes the original intake filter/tubing and disconnects its sensors and coolant-overflow tube, then restores all original components and both battery connections. No new sensors are supplied. Cold hump-coupling directions differ from the hot coupling instruction.
What is the clamp torque?The standalone manual says tighten until the clamp spring is compressed, without numerical torque or a mileage interval. A later combo cold-page revision adds 100β200 miles and possible fan-shroud trimming; confirm the applicable revision.
Are all manual contents and installation steps consistent?Manufacturer instructions explicitly name F-250/F-350 2003β2007 with the 6.0L Power Stroke. Exact engine-specific retailer tables additionally name Excursion 2004β2005 and F-450/F-550 2004β2007. That additional detail is retailer evidence, not a manufacturer-explicit full trim/chassis table. Named Excursion trims still require the actual 6.0L diesel and connection/clearance checks. The standalone October 2012 cold manual lists four 3.5-inch T-bolt clamps and no plug. The February 2017 cold page linked under the combo lists four 3.25-inch clamps, one plug, possible fan-shroud trimming and a 100β200-mile recheck. Confirm actual supplied revision, clamp fit and sealing. Retailers conflict on 2003 F-450/F-550 coverage; that year is withheld pending exact chassis proof, not declared physically incompatible.
Does a threaded port include a water/methanol system?No. An accessory port does not include or universally approve a controller, nozzle, pump, sensor or injection system. Seal unused ports as instructed.
Is this kit CARB exempt?The current primary pages and linked manuals state these products are not CARB exempt and are unavailable for purchase in California or use on vehicles registered with the California DMV.
Installation Instructions
- Read the exact manufacturer instructions for 46-20109, verify the actual engine, supplied parts and every unresolved source conflict before disassembly.
- With batteries disconnected, disconnect original intake-tube sensors and the coolant-overflow tube. Remove the original air filter and intake tubing for access, retaining them for reuse.
- Loosen the two original cold-tube clamps and remove the original tube. Fit the supplied couplings to the replacement tube and verify the actual clamp revision.
- The standalone cold manual gives directional hump-coupling instructions: the manifold-end coupling bead faces the manifold; the tube-end coupling bead faces the tube inlet. Do not replace these directions with the hot-pipe bead instruction.
- Resolve unused-port sealing using the applicable supplied instructions. The later combo cold page lists a plug and thread sealant; the older standalone list omits a plug. Confirm the actual hardware before operation.
- Install the cold tube and check fan-shroud clearance. The later cold component page warns that clearance is limited and shroud trimming may be required. Verify the actual interference and applicable instructions before any cut; no cut dimension is invented.
- Tighten spring-loaded clamps as directed without inventing numerical torque. Restore original filter/intake tubing, sensors, coolant-overflow tube and both battery connections. Follow the applicable supplied revision recheck guidance; the later combined-kit cold page specifies approximately 100β200 miles.
46-20109: inspect every connection and resolve the documented kit discrepancies before operation.
California Proposition 65 Warning
California Proposition 65 warning: this product can expose you to chemicals known to the State of California to cause cancer and reproductive harm.
aFe
Shop aFe POWER intake systems, replacement filters, exhaust components, BladeRunner cooling parts and CONTROL chassis accessories at Black Ops Auto Works. Compare Momentum GT, Track Series and Magnum FORCE intake applications alongside Pro DRY S and Pro 5R filter choices. Choose a complete upgrade or a service component for the system already on your car, truck or SUV.Choose Your aFe Intake and FilterMomentum GT, Track Series and Magnum FORCECompare the intake housing, tubing, filter arrangement and finish offered for your engine. The collection includes Momentum GT applications, selected carbon-fiber Track Series systems and Magnum FORCE configurations. Each package supplies its own combination of induction components, so choose the design for the installation you want.Pro DRY S or Pro 5R Filter MediaPro DRY S uses oil-free media and skips the re-oiling step during service. Pro 5R is an oiled filter option with a different maintenance procedure. Choose a media configuration aFe off...
View aFe Products
Forced Induction
Shop forced induction parts, turbochargers, supercharger kits, intercoolers and boost-control components at Black Ops Auto Works. Explore direct-fit upgrades and components for custom builds, plus blow off valves, wastegates, charge pipes, turbo inlets and replacement hardware. Match your engine, existing equipment and manufacturer part number to choose the right component for the job.The collection also includes Nitrous Express nitrous systems and Snow Performance water-methanol injection products. These are separate power-adder and charge-cooling options with their own fuel, control and installation requirements. A shared vehicle application does not make every component in a boosted build interchangeable.Shop Forced Induction Parts by SystemStart with the part of the system you are replacing or upgrading. A complete vehicle-specific kit, a standalone turbocharger and a replacement valve seal kit are different purchases; check the contents of the exact listing. Product family Wha...
View Forced Induction Products
Ford Excursion Parts and Accessories
Shop Ford Excursion parts for suspension, brakes, diesel repair and exterior projects at Black Ops Auto Works. Compare Bilstein or Rancho shocks, PowerStop brake kits, Road Armor bumpers and engine-specific service components. Build your order around the actual engine, drivetrain and installed ride height.Shock Service and Lifted-Suspension PlanningBilstein 4600 rear and Rancho RS9000XL front titles name Excursion applications, alongside Skyjacker shock and stabilizer references. Match exact axle position, drivetrain, mounts and current suspension height. A shock or steering stabilizer is separate from a spring or complete lift system. Other-model lifted-shock titles require explicit Excursion application and matching travel requirements.PowerStop Brakes and Exterior ChoicesPowerStop references distinguish front and rear Z36 Truck & Tow kits with calipers, plus separate caliper and rotor service parts. Match actual axle, brake dimensions and complete kit contents. Road Armor win...
View Ford Excursion Parts and Accessories Products
Ford F-250 Parts and Accessories
Shop Ford F-250 exhaust, cooling, brake and chassis references at Black Ops Auto Works. Compare Borla gasoline exhaust applications, Powerstroke service components, Bilstein reservoir shocks and Wilwood front-brake references for a defined truck build or repair. Match exact generation, engine, drivetrain, cab, wheelbase and installed suspension first.Gasoline Exhaust or Powerstroke Cooling ServiceThe Borla S-Type cat-back title names a 7.3L gasoline, crew-cab short-bed, specified-wheelbase and single-rear-wheel application. Match every configuration detail before comparing exhaust choices. aFe radiator and Sinister coolant-feed references name distinct 6.7L Powerstroke applications, while a BD Diesel manifold names an older 7.3L Powerstroke. Gasoline and diesel references require separate engine, production and installed-connection checks.Suspension, Steering and Brake-System ChoicesBilstein reservoir-shock, Zone diesel front-coil, Tuff Country spring or bracket and Synergy steering...
View Ford F-250 Parts and Accessories Products
Ford F-250 Super Duty Parts and Accessories
Shop Ford F-250 Super Duty parts for suspension upgrades, engine service and truck accessories at Black Ops Auto Works. Compare ICON systems, KYB shocks, Fleece fuel-filter assemblies and Mishimoto transmission coolers. Match generation, gas or diesel engine, drivetrain and installed suspension to the work being planned.ICON Systems and Shock-Service ChoicesICON titles separate production ranges, gas and diesel applications, stages and coilover conversions. Define the desired ride-height and complete suspension plan before comparing included arms, shocks, springs and expansion-pack contents. KYB references distinguish front/rear positions, production and drivetrain; preserve any chassis-cab exclusion. A spacer, stabilizer kit or component box is separate from a complete specified system.Powerstroke Filtration and Cooling ServiceFleece under-bed and engine-mounted fuel-filter assembly titles describe different locations and application ranges. Identify the actual engine, production a...
View Ford F-250 Super Duty Parts and Accessories Products
Ford F-350 Parts and Accessories
Shop Ford F-350 brake, cooling, suspension and axle references at Black Ops Auto Works. Compare DFC brake-service applications, Powerstroke cooling components and Bilstein or Tuff Country chassis references. Identify the truckβs generation, engine, drivetrain, body and actual installed axles before selecting a repair or build package.Brake Service Across Different ChassisDFC rotor and drum titles include older 2WD or 4WD F-350 applications explicitly excluding Super Duty. Match the actual hub, caliper or drum assembly and dimensions and retain those exclusions. Shared E-Series or other-make hydraulic references require explicit F-350 coverage. Choose axle-specific service and review supplied shoes, pads, hardware or hoses separately.Powerstroke Cooling and Engine ComponentsaFe radiator and Sinister turbo-coolant-feed titles name specific 6.7L Powerstroke applications, while a BD passenger-side manifold names an older 7.3L Powerstroke application. Match actual engine, production, cha...
View Ford F-350 Parts and Accessories Products
Ford F-350 Super Duty Parts and Accessories
Shop Ford F-350 Super Duty suspension, cooling, fuel-service and truck-accessory references at Black Ops Auto Works. Compare ICON suspension systems, Fleece filter assemblies, Mishimoto coolers and cab-access choices around your truckβs intended use. Keep pickup or chassis-cab identity, single or dual rear wheels, engine and current suspension explicit.Suspension System or Shock-Service OrderICON titles separate generations, gas/diesel applications, stages and coilover conversion packages. Compare the complete spring, shock, arm and expansion-pack contents after the installer confirms the desired setup. KYB MonoMax and other shock references specify positions and configurations; a title excluding chassis cab must retain that exclusion. Hellwig rear-bar coverage and steering-stabilizer references need separate drivetrain and mounting checks.Fuel, Cooling and Exhaust ComponentsFleece engine-mounted and under-bed filter assemblies service different locations and production ranges. Mish...
View Ford F-350 Super Duty Parts and Accessories Products
Ford F-450 Parts and Accessories
Shop Ford F-450 suspension, Powerstroke-service and truck-accessory references at Black Ops Auto Works. Compare Air Lift or Firestone helper-spring applications, engine-specific cooling parts and bed or cab protection. Identify pickup versus commercial chassis, engine, drivetrain and body before choosing a service or upgrade plan.Helper Springs and Suspension ComponentsThe Air Lift 7500 XL Ultimate title specifies 2023+ F450 4WD DRW non-commercial coverage. Firestone rear-kit titles name different production ranges, while SES references provide a separate suspension inquiry. Match exact chassis, actual suspension, mounting and body clearances. A Fabtech driver-side coilover or component box is separate from a complete suspension system; confirm every required side, box and supporting component.Powerstroke Cooling and Transmission ServiceSinister coolant-feed, CSF charge-air-cooler and Mishimoto intercooler references name different engine and production applications. ATS valve-body ...
View Ford F-450 Parts and Accessories Products
Ford F-550 Parts and Accessories
Shop Ford F-550 diesel-service, cooling and cab-accessory references at Black Ops Auto Works. Compare CSF or Mishimoto charge-air components, engine-specific MAHLE rebuild choices and filter or lighting references. Match exact chassis, engine, production and body equipment before defining the service order.Powerstroke Charge-Air and Cooling ServiceCSF and Mishimoto titles name specific 6.4L charge-air-cooler or intercooler applications; separate hot-side boots identify individual repair locations. Mishimoto 6.0L hose and Sinister charge-pipe references require their own exact engine and chassis coverage. Match actual turbo, pipe dimensions, connections and supplied clamps. A cab-and-chassis ATS turbo title must retain that application distinction.MAHLE Rebuild and Filtration ChoicesMAHLE pistons and rings span different Powerstroke engines, sizes and compression-height specifications. Cometic gaskets require the correct engine, bank, bore, thickness and installed hardware. Have the ...
View Ford F-550 Parts and Accessories Products
Intercooler Components
Shop intercoolers, charge pipes, couplers, fabrication cores and related charge-cooling hardware at Black Ops Auto Works. Compare Mishimoto, aFe, do88, CSF, Wagner, Garrett, GrimmSpeed, AMS and other listed references for the actual cooling system. Choose a complete kit or identify the specific component being replaced before building the order.Complete Assemblies Versus Fabrication CoresThis selection includes complete vehicle-specific intercoolers and kits as well as individual components. AMS high-mount F-150 references, GrimmSpeed top-mount kits and do88 packages have their own installation scope. Compare actual supplied pipes, seals and brackets rather than assuming every cooler package is identical.Garrett air-to-air and air-to-liquid cores serve defined cooling architectures and fabrication projects. A bare core requires a compatible complete installation; it is separate from a finished vehicle-specific kit. Core size or a supported-power designation does not guarantee the en...
View Intercooler Components Products
Intercooler Pipe Kits
Shop charge pipes, boost-tube systems, throttle-body hoses and intercooler plumbing at Black Ops Auto Works. Compare aFe, Mishimoto, do88, Injen, WCFab, GrimmSpeed, PERRIN and other listed references for the actual turbo, cooler and intake arrangement. Choose a single pipe or a complete routing package before comparing finish and nominal diameter.Hot-Side, Cold-Side and Throttle ConnectionsHot-side pipes carry compressed air from the turbo toward the cooler, while cold-side references connect the cooled-air path toward the engine. A throttle-body hose is a more specific connection piece. Select the actual location rather than assuming every pipe kit replaces both sides.Injen Cobalt SS/Dart, GrimmSpeed WRX, aFe Jeep/Ram HO and APR Q3 hose references have distinct application and connection requirements. Compare retained factory pieces and the exact kitβs couplers, brackets and sensor fittings.do88 Cooler and Throttle-Body Configurationsdo88 Audi RS3/TT RS and MQB pressure-pipe refere...
View Intercooler Pipe Kits Products