Full-Race 2015-2016 Ford F-150 3.5L EcoBoost Intercooler Kit

Overview

The Full-Race 2015-2016 Ford F-150 3.5L EcoBoost Intercooler Kit is the highest-flowing charge-air-cooler system ever developed for the platform. A 3.5″ thick bar-and-plate core, hand-fabricated steel mounting beam, and cast aluminum Y-pipe replace the anemic factory stack with hardware built for real boost — +90°F cooler intake temps than OEM and less than 1 psi of pressure drop at 700+ hp airflow rates.

This is the kit Full-Race built around the real-world failure modes of EcoBoost tuning: intake temps climbing into the 220°F+ range on third-gear pulls, OEM charge piping ballooning under ~25 psi, BOV leaking every modest spike. Installing this kit solves all three in one pass. It’s the foundation you build the rest of your EcoBoost combo on.

Fitment

Performance Specs

Construction

What’s Included

• Full-Race high-flow front-mount intercooler core
• Hand-fabricated steel mounting beam + horn relocation bracket
• Mandrel-bent aluminum charge piping (hot & cold side)
• Cast aluminum Y-pipe
• Complete hardware kit — 2-ply silicone couplers, T-bolt clamps, mounting brackets
• Powder coat finish (Black or Silver per your selection above)
• OEM sensor + purge solenoid fittings retained — plug-and-play on factory electronics
• Printed install instructions (applicable to 2015+ F-150 V2 + 2017+ Raptor platforms)
• Optional add-ons per your dropdown selections: Turbosmart BOV, CSF Radiator, Full-Race Transmission Cooler
• 1-year comprehensive warranty against manufacturing defects

Installation Notes

1. Install difficulty — straightforward bolt-on, but budget a full afternoon for first-timers. The factory plastic bumper core support comes out; Full-Race’s steel beam goes in its place.
2. Required tools — metric hex (5/6/8 mm), sockets (8/10/13 mm), torque wrench, trim removal tools for bumper pull, hose pliers for OEM coupler removal.
3. Do the full system at once — don’t install the core without the charge piping. OEM plastic pipes ballooning while the new core holds pressure is a guaranteed boost leak right after install.
4. Horn relocation — one of the factory horns needs to move to accommodate the larger core. The relocation bracket + hardware is in the kit.
5. BOV timing — if you’re adding the Turbosmart upgrade, do it during install. Retrofit later means dropping the cold-side charge pipe again.
6. Retune recommended — pull a fresh SCT / Livernois tune after install. The lower IATs let you run more timing safely; you’ll leave HP on the table without a revised map.
7. Drain coolant if adding the CSF radiator — factory coolant is spec’d for 50-50 ethylene glycol, capacity ~3 gallons. Recycle the old fluid properly.

Recommended Supporting Mods

Customers typically pair this intercooler kit with:

• Turbosmart Vee Port EM BOV — available via the dropdown above, or search “Turbosmart Vee Port”
• CSF Aluminum Radiator — available via the dropdown above
• Full-Race 30% oversized transmission cooler — available via the dropdown above
• K&N oil catch can / air-oil separator — keeps oil vapor out of the fresh charge path
• NGK Ruthenium spark plugs — gapped tighter for boost; OEM gap blows out above stock boost
• SCT X4 or Livernois MyCalibrator — tune the ECU for the new IATs, more timing, adjusted fuel trims
• AFE Momentum GT cold air intake — matches the flow step-up on the inlet side

Installation & Support

Based in Thousand Oaks, CA. Shop rate \$250/hr if you want us to install and tune. Call 805-267-9762 or tap “Talk to Expert” to coordinate. Full-Race authorized dealer — all warranty claims route through us, not the supplier.

One-year Full-Race warranty covers manufacturing defects on the core, beam, piping, and Y-pipe. Powder coat is cosmetic and handled separately by the coating vendor.