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BladeRunner charged-air intake inlet for the exact engine
The aFe 46-10061 is the BladeRunner two-manifold charged-air kit for the specified 1999.5–2003 Ford 7.3L Power Stroke diesel application. Cast A356-T6 aluminum and Multiple Directional Vane passages serve the charge-air path; this is not a stainless exhaust header or a polished-tailpipe assembly. Both the intake inlet and turbo outlet manifold are supplied, with original heater, sensor and coupling hardware retained as directed.
Key Features
- Correct intake/charge-air function replaces unsupported exhaust material, tailpipe and collector claims.
- The current primary rounds the individual comparisons to 18% intake and 15% turbo outlet; the manual's chart shows 18.3% and 14.8%. These are separate flow measurements, not a summed system gain or guaranteed engine power.
- Six 1/8 NPT plugs and two brass hose fittings are listed, while original heating element and temperature sensor are reinstalled.
- Individual mounting, hose-clamp and threaded-component torques are not interchangeable; the exact manual governs each named fastener.
- The explicit 1999.5 start remains visible; no engine/production pseudo-trim is fabricated.
Fitment
| Years | Model | Exact engine / requirements |
|---|---|---|
| 1999.5–2003 | Ford F-250 / F-350 / F-450 / F-550 | 7.3L Power Stroke diesel with exact later-1999 interface; year-only 1999 rows require production verification |
46-10061: The exact current page and manual start at 1999.5 for the 7.3L Power Stroke F-250/350/450/550. A whole-year 1999 search row does not certify early-1999 hardware, so verify the actual production configuration without inventing a midyear pseudo-trim. This is a two-manifold package, including a turbo outlet and an intake inlet, not one exhaust manifold.
Specifications
| Detail | Value |
|---|---|
| Manufacturer Part Number | 46-10061 |
| Configuration | One intake manifold plus one turbo outlet manifold, support bracket, six plugs, three mounting screws and two brass fittings |
| Construction / airflow path | Cast A356-T6 aluminum charged-air components with MDV passages; not mandrel-bent exhaust tubing |
| Finish | Manufacturer black-finished cast components; no polished exhaust tip is supplied |
| Fasteners / torque | The exact manual specifies 18 ft-lb for the two support-bracket screws, 16 ft-lb for the retained heating element/temperature sensor and straight brass hose nipple installed in that step, and 9 ft-lb for the two intercooler tube coupling clamps. It calls for firmly tightening the turbo V-band and checking components, without a numeric V-band value or mileage interval. Do not transfer 16 ft-lb to every plug or unspecified flange screw. |
| Grid heater / original components | Remove and reinstall the original heating element and temperature sensor, reconnect their wiring and the original hoses and restore the boost-control module. Original Y-inlet and turbo V-band/clamp connections are reused; replacement Y couplings are conditional service parts, not included new hoses. This is not a heater-delete instruction. |
| Emissions | The current primary cites CARB EO D-550-10. Its official indexed table lists the exact 7.3L part for 1999–2003 Ford F-series diesel pickup application; actual engine and the manual's 1999.5–2003 configuration restrictions still govern. Do not extend the exemption to unrelated models, changed tuning or altered emissions hardware. |
What's Included
- One turbo outlet manifold, 05-60030, and one intake manifold, 05-60031; one support bracket, 05-60032.
- Six 1/8 NPT plugs, 03-50029; two hex-head cap screws, 03-50212; one flange screw, 03-50182.
- One straight brass hose nipple, 03-50191, and one 90-degree brass fitting, 03-50213. The installation identifies 3/8-16 tapped engine holes for the two support-bracket cap screws.
- Original heating element, temperature sensor, hoses, Y-inlet connections, turbo V-band and boost-control module are retained. No new replacement coupling set is promised.
- No air filter, exhaust header/tip, new sensor or complete injection system appears in the exact bill of materials.
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 intake-inlet configuration; individual engine generations use different manifolds and hardware.
- Match actual intake inlet, grid heater and intercooler coupling interfaces. A shared engine size does not approve another model or year.
Frequently Asked Questions
What is the 46-10061?A cast aluminum intake-inlet and turbo-outlet manifold kit for the exact Ford 7.3L diesel application, not a single exhaust manifold.
Which year and engine limitations matter?The exact current page and manual start at 1999.5 for the 7.3L Power Stroke F-250/350/450/550. A whole-year 1999 search row does not certify early-1999 hardware, so verify the actual production configuration without inventing a midyear pseudo-trim. This is a two-manifold package, including a turbo outlet and an intake inlet, not one exhaust manifold.
Are new sensors, heaters or couplings included?Remove and reinstall the original heating element and temperature sensor, reconnect their wiring and the original hoses and restore the boost-control module. Original Y-inlet and turbo V-band/clamp connections are reused; replacement Y couplings are conditional service parts, not included new hoses. This is not a heater-delete instruction.
Which hardware must be matched to this exact kit?Two manifold castings, a support bracket, six plugs, two cap screws, one flange screw and two brass fittings. Original sensors/heater and clamp interfaces remain required.
What torque and inspection instructions apply?The exact manual specifies 18 ft-lb for the two support-bracket screws, 16 ft-lb for the retained heating element/temperature sensor and straight brass hose nipple installed in that step, and 9 ft-lb for the two intercooler tube coupling clamps. It calls for firmly tightening the turbo V-band and checking components, without a numeric V-band value or mileage interval. Do not transfer 16 ft-lb to every plug or unspecified flange screw.
Do the manifold flow figures guarantee horsepower?No. Component flow measurements are not guaranteed engine power, fuel economy, EGT reduction or permission to increase boost.
Does this replace or disable emissions or heater equipment?The exact instructions reinstall the original heating element, temperature sensor, hoses and boost-control module; this is not a heater-delete or emissions-hardware removal kit.
What emissions scope is cited?The current primary cites CARB EO D-550-10. Its official indexed table lists the exact 7.3L part for 1999–2003 Ford F-series diesel pickup application; actual engine and the manual's 1999.5–2003 configuration restrictions still govern. Do not extend the exemption to unrelated models, changed tuning or altered emissions hardware.
Installation Instructions
- Read the exact manufacturer instructions for 46-10061, verify the actual engine, supplied parts and every unresolved source conflict before disassembly.
- Cool and secure the vehicle, disconnect negative battery terminals and remove the boost-control module. Disconnect the rubber boot/hose, temperature sensor and heating-element wires.
- Remove and retain the heating element and temperature sensor. Disconnect the lower manifold hose, turbo V-band and both intercooler tube coupling connections, then release the two upper Y-inlet clamps.
- Remove the original intake manifold carefully without allowing debris into the open plenums. Replace original Y couplings only if needed with the exact Ford service part identified by the manual; those replacement couplings are not supplied in this kit.
- Install the support bracket using the two supplied cap screws at the 3/8-16 tapped engine holes and torque those screws to 18 ft-lb.
- Apply the instructed thin pipe-sealant tape layer to the threaded fittings. Fit all six plugs and the 90-degree fitting, then reuse the original Y-inlet band/clamp arrangement.
- Install the retained heating element, temperature sensor and straight brass nipple. The manual assigns 16 ft-lb to the items installed in that step. Reconnect the temperature sensor before setting the inlet in its couplings.
- Align the lower inlet to its support bracket and fit the supplied flange screw. Adjust the original Y coupling clamps for access and tighten after alignment; do not infer a separate numeric flange-screw/Y-clamp value.
- Reconnect the cold intercooler tube coupling at 9 ft-lb and restore the original wires and hoses. Seat the turbo outlet manifold evenly at the turbo and firmly tighten the retained V-band; the manual gives no numeric V-band torque.
- Reconnect the hot intercooler coupling at 9 ft-lb, reinstall the original boost-control module and reconnect the batteries. Check all components and follow applicable EO identification requirements; no mileage interval is published.
46-10061: 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.
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