aFe BladeRunner GT Series Intercooler

2003–2007 Dodge Ram 2500 / Ram 3500 Diesel

Part #: 46-20011

Overview

The aFe BladeRunner GT Series Intercooler is a premium performance upgrade engineered specifically for 2003 to 2007 Dodge Ram 2500 and Ram 3500 diesel trucks. Designed to optimize airflow and significantly reduce intake air temperatures, this intercooler enhances combustion efficiency, resulting in noticeable gains in horsepower and torque. It is an ideal solution for diesel truck enthusiasts looking to improve power output and reliability without sacrificing durability.

Compared to factory intercoolers that utilize traditional tube and fin cores, the BladeRunner GT Series features a robust 3-inch thick bar and plate core that maximizes airflow and heat dissipation. This advanced design ensures your engine receives cooler, denser air, which is critical for maintaining peak performance under heavy load and high boost conditions.

Key Features

Built with cutting-edge technology and premium materials, the BladeRunner intercooler delivers superior performance and long-lasting reliability. Key features include:

• Multiple Directional Vane (MDV) Technology: Enhances airflow distribution across the entire core face for more efficient heat transfer and lower intake air temperatures.
• Massive 3-inch Thick Bar and Plate Core: Provides greater airflow capacity and improved heat dissipation compared to factory tube and fin designs.
• Tag-Welded Aluminum End Tanks: Crafted with 100% TIG welding for exceptional strength and durability under high boost pressures.
• Stainless Steel Spring Loaded T-Bolt Clamps: Ensure secure, constant tension for reliable sealing and leak prevention.
• 5-Ply Reinforced Silicone Hump Couplings: Designed to withstand high boost levels while resisting cracking and leaks.
• Four Pre-Tapped 1/8-inch NPT Ports: Ready for integration with nitrous oxide systems, boost gauges, or other performance accessories.
• Test Pressure Rated at 200 PSI: Suitable for demanding high boost applications without risk of failure.
• Comprehensive Installation Instructions: Included for a hassle-free upgrade process.
• Limited 2-Year Warranty: Provides peace of mind with quality assurance from aFe.

Construction & Design

The BladeRunner GT Series Intercooler is expertly constructed with a high-grade aluminum bar and plate core, which offers superior heat dissipation and airflow compared to conventional tube and fin cores. The thick 3-inch core design maximizes surface area for cooling, ensuring intake air remains dense and cool even under extreme conditions.

Aluminum end tanks are precision tag-welded by certified craftsmen using 100% TIG welding techniques, delivering exceptional strength and durability to withstand the rigors of high-performance diesel applications. The intercooler’s exclusive MDV technology incorporates directional vanes inside the end tanks to channel airflow evenly across the entire core surface, maximizing heat transfer efficiency and reducing intake air temperatures.

Reinforced silicone couplings and stainless steel clamps further enhance reliability by providing secure, leak-free connections capable of handling high boost pressures.

Installation & Fitment

The aFe BladeRunner GT Series Intercooler is a direct-fit replacement for Dodge Ram 2500 and Ram 3500 diesel trucks from model years 2003 through 2007. Installation is straightforward and requires no major modifications, utilizing the included hardware and detailed instructions for a smooth upgrade experience.

Pre-tapped ports allow easy integration of additional performance accessories such as nitrous oxide systems or boost gauges, making this intercooler a versatile choice for enthusiasts seeking to expand their setup.

What's Included

• BladeRunner GT Series Intercooler core with tag-welded aluminum end tanks
• 5-ply reinforced silicone hump couplings
• Stainless steel spring loaded T-bolt clamps
• Four pre-tapped 1/8-inch NPT ports
• Comprehensive installation instructions

Ideal For

This intercooler is perfect for diesel truck owners who want to maximize the performance of their 2003–2007 Dodge Ram 2500 or Ram 3500. Whether upgrading for towing, hauling, off-road use, or high-boost applications, the BladeRunner intercooler delivers cooler intake air and improved airflow to support increased horsepower and torque. It is also an excellent choice for enthusiasts running nitrous oxide or other performance enhancements who demand a durable and efficient intercooler solution.

aFe POWER (Advanced FLOW Engineering) offers dyno-proven intake, filtration, and exhaust upgrades aimed at measurable performance gains. The brand’s lineup is geared toward enthusiasts looking for better airflow, improved sound, and durable materials—from cold air intakes to stainless exhaust systems for street and track applications.