Click to zoom in
Bigger Core, Lower Temps, More Confidence for the 2003-2005 Ford Excursion
The aFe BladeRunner Street Series heavy-duty radiator 46-80001 replaces the factory heavy-duty radiator with a larger-core, higher-capacity unit engineered to maintain safe coolant temperatures under the sustained loads that overwhelm the OEM cooler. Built with an expanded core design compared to the factory unit, this is a direct bolt-on replacement that uses factory mounting points, hoses, and connections without any cutting or custom fabrication. For diesel trucks, towing rigs, and high-output builds running harder than the factory heavy-duty radiator was designed for, the 46-80001 is a critical upgrade.
Key Features
- Expanded core design for superior thermal dissipation
- Direct bolt-on using factory mounting brackets and hose connections
- Higher coolant capacity than OEM for improved thermal buffering
- Compatible with factory coolant hoses and fittings
- Designed for high-load applications: towing, diesel trucks, and performance builds
- Backed by aFe Power BladeRunner limited manufacturer warranty
Fitment
| Year Range | Make | Model | Trim |
|---|---|---|---|
| 2003-2005 | Ford | Excursion | Eddie Bauer |
| 2003-2005 | Ford | Excursion | Limited |
| 2003-2005 | Ford | Excursion | XLT |
| 2003-2007 | Ford | F-250 Super Duty | XL |
| 2003-2007 | Ford | F-250 Super Duty | XLT |
| 2003-2007 | Ford | F-350 Super Duty | King Ranch |
| 2003-2007 | Ford | F-350 Super Duty | Lariat |
| 2003-2007 | Ford | F-350 Super Duty | XL |
| 2004-2005 | Ford | Excursion | XLS |
| 2004-2007 | Ford | F-250 Super Duty | Harley-Davidson Edition |
| 2004-2007 | Ford | F-250 Super Duty | King Ranch |
| 2004-2007 | Ford | F-350 Super Duty | Harley-Davidson Edition |
Specifications
| Detail | Value |
|---|---|
| Part Number | 46-80001 |
| Brand | aFe Power |
| Product Line | aFe BladeRunner Street Series |
| Mounting | Direct bolt-on, OEM hardware |
| UPC | 802959463864 |
What's Included
- aFe BladeRunner heavy-duty radiator (46-80001)
- All required hardware and fittings
- Installation instructions
Frequently Asked Questions
Will this radiator work with my existing overflow reservoir?Yes. The 46-80001 is designed to interface with the factory coolant overflow reservoir using OEM-compatible hose fittings. No reservoir modification or replacement is required in most applications.
Should I flush the factory coolant before installation?Yes. Whenever replacing a radiator or cooler, flush the entire cooling system with clean distilled water before installing the new unit. This ensures no old degraded coolant or debris is introduced into the fresh system.
What coolant type should I use with this radiator?Use the coolant type and concentration specified in your owner's manual. For diesel and high-output applications, a fully formulated extended-life coolant with a supplemental coolant additive (SCA) package is recommended. Do not mix different coolant chemistries.
Does this radiator fit with my aftermarket fan clutch or electric fan upgrade?The 46-80001 is designed around OEM fan placement and clearances. For electric fan upgrades, confirm radiator thickness and fan positioning against your specific fan kit before ordering.
Will this help with coolant temperature issues while towing?Yes. The expanded core capacity of the 46-80001 is specifically designed to address coolant temperature excursions during sustained towing or high-load operation that the factory radiator cannot adequately manage.
Is this compatible with my transmission cooler lines?Many OEM radiators have integrated transmission cooler ports. If the 46-80001 replicates these ports, your factory trans cooler lines will connect directly. Verify this with the product listing or contact us before ordering if you have an integrated cooler.
What is the warranty on this radiator?aFe Power provides a limited manufacturer warranty on BladeRunner radiators covering defects in materials and workmanship. Warranty does not cover damage from improper installation, overheating events, or using incompatible coolant chemistry. Contact us for full warranty documentation.
How long does installation typically take?Most experienced installers complete a radiator swap in two to four hours. Budget additional time if the vehicle has significant rust on hose connections or a complex fan shroud mounting system.
Installation Overview
- Allow the engine to cool completely and safely lift the vehicle for access to the front fascia
- Drain the cooling system using the factory drain petcock or lower radiator hose
- Remove the upper and lower radiator hoses and any transmission cooler lines
- Disconnect the fan shroud and carefully remove it before lifting the radiator out
- Remove the factory mounting bolts and lift the radiator straight up and out
- Compare the new 46-80001 to the old unit for mounting hole alignment before installation
- Lower the new radiator into position and secure all mounting hardware
- Reinstall the fan shroud, reconnect all hoses, and transfer any transmission cooler line fittings
- Refill with fresh coolant at the correct concentration, start the engine, and bleed the system of air
- Check for leaks at all connections after reaching operating temperature
WARNING: This product can expose you to chemicals including lead and phthalates, which are known to the State of California to cause cancer and reproductive harm. For more information go to www.P65Warnings.ca.gov.
aFe
Shop aFe Power performance parts at Black Ops Auto Works for vehicle-specific airflow, filtration, exhaust, cooling, suspension, and diesel performance upgrades. aFe Power, also known as Advanced FLOW Engineering, is trusted by performance enthusiasts for cold air intakes, air filters, cat-back exhaust systems, DPF-back exhaust systems, axle-back exhausts, throttle body spacers, intercoolers, charge pipes, differential covers, sway bars, wheel spacers, and diesel truck upgrades. Whether you drive a daily driver, diesel truck, off-road build, turbo car, muscle car, SUV, or track-focused performance vehicle, Black Ops Auto Works carries aFe Power parts designed to improve airflow, throttle response, exhaust flow, cooling efficiency, drivetrain durability, and overall performance. Shop aFe Power Parts by Category Browse aFe Power upgrades across popular performance categories, including: aFe cold air intakes aFe air filters aFe cat-back exhaust systems aFe axle-back exhaust systems aF...
View aFe Products
Cooling
Shop performance cooling parts at Black Ops Auto Works for premium radiators, thermostat housings, thermostats, coolant reservoirs, expansion tanks, radiator hoses, oil coolers, transmission coolers, fans and shrouds, water pumps, and thermal management upgrades for street, track, towing, diesel, and high-horsepower builds. Whether you are trying to control engine temps, improve reliability, or support demanding performance use, this collection is built around proven cooling-system upgrades for serious enthusiasts. Shop Cooling Parts by Category Browse automotive cooling system components across key product categories, including: Radiators Coolant reservoirs and expansion tanks Thermostat housings and thermostats Radiator hose kits and silicone coolant hoses Oil coolers and oil cooler accessories Transmission coolers Coolant bypass kits and coolant filters Fans and shrouds Radiator caps Water pumps Radiator shrouds, radiator stays, and cooling plates Thermal wrap, thermal tape, an...
View Cooling Products
EGR Coolers
An EGR cooler is a critical emissions and engine longevity component that recirculates a portion of exhaust gases back into the intake stream at a reduced temperature, lowering combustion temperatures and reducing NOx output in diesel and some gasoline engines. Factory EGR coolers are a known failure point on several popular diesel platforms, particularly the 6.0L and 6.4L Ford Power Stroke engines where coolant contamination from a cracked or failed cooler can cause catastrophic engine damage if not addressed promptly. Diesel truck owners, fleet operators, and performance builders choose upgraded or replacement EGR coolers to restore reliable function, improve coolant system longevity, and in some cases delete the EGR system entirely for off-road competition use. Understanding whether an upgrade or a delete solution is right for your application depends on the vehicle's intended use, state emissions requirements, and whether the truck is under warranty.Popular UpgradesTop-selling E...
View EGR Coolers Products
Engine
This engine parts collection covers oil catch cans, thermostats, thermostat housings, radiator components, coolant accessories, engine covers, fuse box covers, cap covers, throttle bodies, supercharger pulleys, idler pulleys, tensioner pulleys, and engine bay dress-up parts for trucks, SUVs, muscle cars, boosted builds, high-horsepower street cars, and performance vehicles that need better reliability, cooling, airflow, oil control, and under-hood styling. The collection is particularly strong for Dodge Challenger, Charger, Durango, Jeep Grand Cherokee Trackhawk, and Ram TRX platforms running 6.2L Hellcat, 6.4L HEMI, and 5.7L HEMI engines, where oil catch can and cooling upgrades address known OEM weaknesses in the PCV and thermal management systems. Import performance platforms including GM LS-based builds, Chevrolet Camaro, and Corvette applications are also represented through Mishimoto, CSF, and ZPE GripTec product lines. Builders who invest in engine bay organization and reliab...
View Engine ProductsLet customers speak for us
Looks pretty nice
Looks pretty nice, pricing was good and the reinforcement is a big plus.
Randy H.
Black Ops Auto Works
I emailed customer service to inquire about when it would be shipped
I emailed customer service to inquire about when it would be shipped. They checked and emailed me with the answer. Customer service is A1
Ralph J.
Black Ops Auto Works
Installation was easy
Installation was easy. The price is good and it looks great on the truck.
Ralph J.
RHO Small Grille Badge
Looks as good as it fits
Looks as good as it fits,
zachary d.
Seibon 70-73 Datsun 240Z OE Carbon Fiber Hood
Nothing like it
I love it great sound and response
Luis P.
Legmaker Dodge Durango HEMI Short Ram CAI 2011-Present 5.7L
Car totally diferent with the whole kit
Car totally diferent with the whole kit. Ive stood next to wide bodies and my car gets more attention at times . Ive bought the kit twice already.
Ding D.
2015-2023 Dodge Charger Carbon Fiber Wind Splitters
Fantastic emblem! Exactly what I was looking for
Fantastic emblem! Exactly what I was looking for. Great quality emblem.
Jacobus S.
Direct Connection Black Metallic Fender Badge
Worked great for my aftermarket hood on my Chrysler 2023 300C
Worked great for my aftermarket hood on my Chrysler 2023 300C. Thanks
Robert G.
Windshield Washer Squirter Relocation Kit Universal
Easy to install and makes car sound even better
Easy to install and makes car sound even better love the winn
Tracy H.
Legmaker Challenger/Charger Hellcat Demon & Redeye Air Intake
Awesome customer support
Awesome customer support. Had multiple issues with fedex and these guys were excellent in helping me sort everything out. The drop springs are great too! I highly recommend
Anonymous
Swift Spec-R Lowering springs Jeep Grand Cherokee 2011-2021
100/100! perfect CF crafted cold air intake for 6
100/100! perfect CF crafted cold air intake for 6.4 jeep .. even makes my AWE exhaust sound even deeper and you cam here this thing sucking when accelerating even at normal speeds🥶
srt.boizzz
Legmaker 392 TH Short Ram Jeep Grand Cherokee SRT 2012-2021
