Ford Performance Intercooler

[DentSurgeon]

I have a 2026 Maverick 2.0. I got the ford performance intercooler. Tried to install it today and it looks like the active shutter assembly has the radiators mounted to it. Has anyone done the swap to the ford performance intercooler? The install instructions from ford were pretty vague on how to remove the actual intercooler. Im hoping the radiator and condenser don’t have to come out. I ran out of time and had to put the truck back together. Any insight appreciated!

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[NycGoose]

I’m getting my suspension changed and then want to do the same upgrade myself. Hoping its not too hard of a job

 

[Grammaton]

I have a 2026 Maverick 2.0. I got the ford performance intercooler. Tried to install it today and it looks like the active shutter assembly has the radiators mounted to it. Has anyone done the swap to the ford performance intercooler? The install instructions from ford were pretty vague on how to remove the actual intercooler. Im hoping the radiator and condenser don’t have to come out. I ran out of time and had to put the truck back together. Any insight appreciated!

You have to remove the entire front bumper support which is 8 nuts and 2 bolts after you remove the headlamps. Also disconnect MAP sensor from Passenger side Intercooler hose before disconnecting intercooler hoses. Make sure to unclip the hood release cable beforehand from top of shroud/shutter then you can remove the whole shroud and shutter system after squeezing and pushing in the upper radiator plastic retainers on each side of the top of shroud/shutters after removing the 4 bolts from the lower support bar.
The Radiator and Condenser aren't removed but you do have to release the plastic clips at the top on each side holding the condenser, so condenser can move a bit up and out to make more room to remove the OEM intercooler.

 

[Chops]

Ford Dealer installed mine. No extra parts required or modifications - “plug & play”. I’m assuming they followed the instructions per Grammatron’s attachment above. Removing the grille & bumper seems like a pain - but worth it!

 

[SteeleMech]

Ford Dealer installed mine. No extra parts required or modifications - “plug & play”. I’m assuming they followed the instructions per Grammatron’s attachment above. Removing the grille & bumper seems like a pain - but worth it!

How much did they charge you?

 

[Automan21]

I just took the bumper off and used the procedure the other intercooler companies follow. Cut and install done. Wasn’t taking that whole carrier off.

 

[DentSurgeon]

You have to remove the entire front bumper support which is 8 nuts and 2 bolts after you remove the headlamps. Also disconnect MAP sensor from Passenger side Intercooler hose before disconnecting intercooler hoses. Make sure to unclip the hood release cable beforehand from top of shroud/shutter then you can remove the whole shroud and shutter system after squeezing and pushing in the upper radiator plastic retainers on each side of the top of shroud/shutters after removing the 4 bolts from the lower support bar.
The Radiator and Condenser aren't removed but you do have to release the plastic clips at the top on each side holding the condenser, so condenser can move a bit up and out to make more room to remove the OEM intercooler.

I just took the bumper off and used the procedure the other intercooler companies follow. Cut and install done. Wasn’t taking that whole carrier off.

Kim

You have to remove the entire front bumper support which is 8 nuts and 2 bolts after you remove the headlamps. Also disconnect MAP sensor from Passenger side Intercooler hose before disconnecting intercooler hoses. Make sure to unclip the hood release cable beforehand from top of shroud/shutter then you can remove the whole shroud and shutter system after squeezing and pushing in the upper radiator plastic retainers on each side of the top of shroud/shutters after removing the 4 bolts from the lower support bar.
The Radiator and Condenser aren't removed but you do have to release the plastic clips at the top on each side holding the condenser, so condenser can move a bit up and out to make more room to remove the OEM intercooler.

so after pushing in upper radiator clips the whole shroud assembly will slide out?

 

[FERALMAVERICK]

Kim

so after pushing in upper radiator clips the whole shroud assembly will slide out?

YES with a little finesse it will separate the 2 tabs are plastic so be careful , once you do that it pretty straight forward

 

[Chops]

How much did they charge you?

Was quoted 3 hours labor by service guy @$199/hr.

I agreed to pay for 1 hour since I was getting my radiator replaced under warranty and the only extra work required would be unboxing the intercooler (5 mins).

I like to DIY - but was happy to pay the $199 and avoid the front end disassembly. Dealer did a great job lining everything back up.

They even had to partially remove my Mabbet fender flares & reattach. Did not charge me for the new 3M tape or adhesive promoter that noted in their job comments.

 

[SteeleMech]

Was quoted 3 hours labor by service guy @$199/hr.

I agreed to pay for 1 hour since I was getting my radiator replaced under warranty and the only extra work required would be unboxing the intercooler (5 mins).

I like to DIY - but was happy to pay the $199 and avoid the front end disassembly. Dealer did a great job lining everything back up.

They even had to partially remove my Mabbet fender flares & reattach. Did not charge me for the new 3M tape or adhesive promoter that noted in their job comments.

Yeah, I have the same Fender flares and was weighing to do it myself or find a mechanic that could do it

 

[Tbone289]

Ford Dealer installed mine. No extra parts required or modifications - “plug & play”. I’m assuming they followed the instructions per Grammatron’s attachment above. Removing the grille & bumper seems like a pain - but worth it!

Bumper/grille removal isn't that bad. I must have done it 20 times trying to get my fog lamps aligned right. Well, once to mount them and several more partially on and off for alignment.

 

[Chops]

Bumper/grille removal isn't that bad. I must have done it 20 times trying to get my fog lamps aligned right. Well, once to mount them and several more partially on and off for alignment.

I bet the 20th time was easier than the first! Learning Curve is both a blessing and a curse

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