PRL Motorsports Intercooler 2021–2025 Ford F-150 3.5L EcoBoost

Overview

PRL Motorsports’ Intercooler for the 2021–2025 Ford F-150 2.7L and 3.5L EcoBoost is engineered to deliver consistent cooling performance under boost, towing, and heavy load conditions. Designed as a direct-fit replacement for the restrictive OEM unit, this intercooler features a high-capacity bar-and-plate core paired with TIG-welded cast aluminum end tanks for maximum thermal efficiency and durability. The PRL bar-and-plate intercooler features a robust core design engineered for consistent cooling performance under demanding conditions. Its heavy-duty construction offers improved impact resistance over the factory tube-and-fin intercooler, making it better suited for real-world driving. Each unit is finished with a durable powder coat to provide enhanced corrosion resistance, ensuring long-lasting performance and appearance.

From dyno testing to real-world towing evaluations, this intercooler has proven its ability to maintain power and keep charge air temps under control—even in the most demanding conditions. In our testing, the PRL intercooler alone produced gains of +21.33 horsepower and +34 lb-ft of torque at 6300 RPM over the stock intercooler. Heat soak testing showed that it retained significantly more power during consecutive pulls, losing 6.3 horsepower and 24.65 lb-ft less torque than OEM.

In a real-world towing test with a 5600 lb trailer, the PRL intercooler reduced charge air temps by 26.5°F at the start of a sustained hill climb, and still held a 20°F advantage over stock at the end. Ambient temps under load post intercooler were reduced by 8°F, easing strain across the entire cooling system.

When paired with the PRL High Volume Intake System, the gains became even more impressive, peaking at +50 horsepower and +40 lb-ft of torque at redline.

Key Features

• High-efficiency bar-and-plate core with optimized fin density

• Cast and machined aluminum end tanks

• TIG-welded construction for long-term durability

• Direct-fit design retains OEM shutters, bypass valve, and Raptor-specific fans
  

• NPT drain plug included for excessive condensation build-up

• Installs with factory mounting points and hardware

• No trimming or modifications required

• 5-Layer Reinforced Silicone Coupler (2021–2025 specific)

• 304 Stainless Steel Clamps

Fitment

• 2021–2025 Ford F-150 3.5L EcoBoost

• 2021–2025 Ford F-150 Raptor

What’s Included

• (1) PRL Intercooler (Silver or Black Finish)

• (1) Cold Side Silicone Coupler – 2021–2025

• (2) Stainless Hose Clamps

• (1) M6 x 1 x 12 JIS Flange Bolt

• (1) 1/8” NPT Plug with Sealant

*Planned submission to SEMA Garage for CARB testing

INSTALL GUIDE