AFE Blade Runner Exhaust Manifolds

The exhaust gases that are from the engine are what drive the turbocharger before the air is drawn into the intake. These gases originate from the exhaust manifold. The exhaust manifold is a critical component to the power that goes to the turbocharger. The more the flow of gases is restricted or uneven, the more the efficiency of the turbocharger will be reduced. AFE BladeRunner Exhaust Manifolds improve the flow characteristics of the exhaust gases while greatly increasing the durability of the exhaust manifold over the original.

Diesel truck owners and performance enthusiasts looking to increase power output across a wide torque curve are smart to think of the AFE BladeRunner exhaust manifold as more than a simple replacement component. It is critical to the integrity of the engine package, and the manifold has a direct effect on the speed and efficiency of the turbo and overall engine performance, as well as its durability under high-torque conditions.

Why Upgrade to an AFE BladeRunner Exhaust Manifold

Just about every factory exhaust manifold on the planet is made from cast iron, due to low cost and design simplification. Factory manifolds on diesel engines can suffer from catastrophic failures, particularly after they've gone through a series of thermal cycles, or when high boost pressures are encountered. These failures can ruin power output, hamper turbocharger performance and negatively affect engine longevity.

Most stock manifolds are damaged in one way or another. Whether it be a puncture, crack or bend the performance of the manifold cannot be optimized. In the undamaged state the manifold can also be detrimental to exhaust gas flow. Length differences between runners and abrupt changes in the path can cause violent turbulence prior to the exhaust gas reaching the turbocharger. This has a direct impact on exhaust energy utilization, resultant spool time, and boost pressure stability.

The AFE BladeRunner exhaust manifolds are built from either cast 304 stainless steel or ductile iron, both of which are significantly more resistant to cracking and thermal fatigue than the standard cast iron used in factory manifolds. Thick wall flanges and reinforcing ribs further address the exact weak points the OEM design ignores. These updates ensure that the gases flow efficiently from the cylinder head to the turbocharger, allowing the turbo to operate in an optimal condition, while significantly strengthening one of the hottest parts of the engine bay.

Engineering Built Around Flow and Durability

The typical material used to build an AFE BladeRunner exhaust manifold is ductile iron or high-silicon molybdenum cast. Diesel engines produce a tremendous amount of heat in the exhaust system and materials must be chosen that can handle the thermal and pressure loads or they will crack and warp. The engines that are used in large tow trucks or have been modified to produce more power also produce more heat and a manifold that can safely handle the additional loads must be built.

The internal design of a BladeRunner manifold is designed to provide a more efficient flow path between the engines cylinders and turbochargers. The manifolds are designed to give a smooth transition with minimal run lengths and strategically located reinforcement to ensure optimal turbocharger geometry. The result is a reduction in gas velocity variation and a higher overall exhaust gas velocity, which translates into more energy being transferred to the turbochargers, leading to quicker spool up and more consistent boost pressure at high engine loads.

Made using advanced high flow precision machining techniques the manifolds are carefully designed to eliminate any unnecessary obstructions while still remaining easy to bolt on. By using carefully machined mounting surfaces they provide a perfect seal for the head, and by reinforcing critical flange areas, the manifold is resistant to warping and twisting due to the intense heat cycling it is subjected to. High flow manifolds improve the all around flow of air and fuel to the engine, which directly contributes to power gain.

AFE BladeRunner Exhaust Manifold for Cummins

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The Cummins engine family is one of the most popular diesel platforms for performance builds, and the exhaust manifold is one of the first components to become a liability when power levels climb. Both the 5.9L and 6.7L Cummins are known for their tunability and massive torque potential, and the factory exhaust manifold simply wasn't designed to keep up.

The OEM manifold is prone to cracking on both engines, particularly when boost pressure and exhaust gas temperatures rise. This is especially common on tuned trucks where the engine is pushing well beyond stock output. The BladeRunner addresses this with a thick wall design and a merged runner layout that reduces backpressure and keeps exhaust gas velocity in an optimal range as it flows to the turbocharger, resulting in faster spool-up, improved throttle response, and lower EGTs.

There are some meaningful differences between the two applications worth noting. The 5.9L manifold is built from cast 304 stainless steel, a premium material with excellent heat and corrosion resistance, and outflows the factory unit by 23% with walls 67% thicker than stock (0.25" vs. 0.15"). The 6.7L manifold is built from ductile iron and outflows the factory unit by an even larger margin of 49%, and additionally features cast-in EGR flanges so the factory EGR system can be retained without modification.

Both manifolds include dual 1/8" NPT EGT probe ports and all hardware needed for installation.

Dodge Ram 6.7L Cummins

• AFE 46-40054 BladeRunner Ported Ductile Iron Exhaust Manifold – 2007.5-2018 Dodge Ram 6.7L Cummins

Dodge Ram 5.9L Cummins

• AFE 46-40011 BladeRunner Stainless Steel Exhaust Manifold – 2003-2007 Dodge Ram 5.9L Cummins

• AFE 46-40012 BladeRunner Ductile Iron Exhaust Manifold – 2003-2007 Dodge Ram 5.9L Cummins

• AFE 46-40034 BladeRunner Ported Ductile Iron Exhaust Manifold – 1998.5-2002 Dodge Ram 5.9L Cummins

• AFE 46-40032 BladeRunner Ductile Iron Exhaust Manifold – 1998.5-2002 Dodge Ram 5.9L Cummins

• AFE 46-40044-1 BladeRunner Ported Ductile Iron Exhaust Manifold – 1994-1998 Dodge Ram 5.9L Cummins

AFE BladeRunner Exhaust Manifold for Power Stroke

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A key component of the BladeRunner exhaust lineup is the manifold designed for Ford's Power Stroke platform. These engines and their work truck applications subject the exhaust manifold to incredible heat load, and even slight increases in exhaust gas temperature or pressure can elevate manifold temperatures to the point where cracking and weld failure become a serious concern. In these applications it is imperative that the exhaust manifold be made from material that is robust and reliable to avoid a potentially costly failure.

Both the 6.0L and 6.4L Power Stroke manifolds are built from ported ductile iron and outflow the factory units by 5%. Both are direct bolt-on replacements compatible with the factory up-pipes, meaning neither the turbocharger down-pipe nor the up-pipes need to be removed during installation. EGT probe ports are incorporated into each manifold for easy installation of gauges or testing equipment, and CNC machined ports match the factory openings for maximum flow without compromising gasket sealing.

The primary difference between the two applications is fitment. The 6.0L manifold includes three additional cast-in bosses for alternate testing points, while the 6.4L manifold is fully compatible with all factory equipment including AC lines, heat shields, and the EGR cooler, making it a true bolt-on upgrade with no ancillary components to deal with.

By maintaining consistent exhaust energy, the turbocharger maintains high efficiency, stable boost levels, and more responsive throttle under load, whether you're on the highway or hauling a heavy trailer.

Ford 6.0L Powerstroke

• AFE 46-40094 BladeRunner Ported Ductile Iron Exhaust Manifolds – 2003-2007 Ford 6.0L Powerstroke

Ford 6.4L Powerstroke

• AFE 46-40124 BladeRunner Ported Ductile Iron Exhaust Manifolds – 2008-2010 Ford 6.4L Powerstroke

Performance Gains Beyond Peak Numbers

While upgrading the exhaust manifold is often overlooked in favor of larger cast wheels, headers and intercoolers, the exhaust manifold has a direct impact on how efficiently the energy contained in the exhaust gases is transferred to the turbocharger. Improving exhaust flow in the most critical part of the system – the source – has a direct benefit to the entire forced induction system.

Drivers may notice more predictable turbo spool behavior and smoother power delivery across the RPM range. In towing scenarios, improved exhaust flow can contribute to steadier boost levels under sustained load. In performance builds, the manifold supports higher airflow demands without becoming a bottleneck.

Just as important is the reduction in the chance of blowout or leak over time. A stronger engine head gasket provides a sense of security especially in high boost applications and high exhaust temperatures.

Designed for Demanding Applications

High-performance AFE BladeRunner exhaust manifolds are ideal for diesel trucks engaged in heavy towing, off-road pulling and high-performance street trucks. Such conditions often result in the excessive heat and cylinder pressure that can breach the integrity of the standard OEM castings.

AFE's High Flow Performance Manifold Upgrade is engineered to be a complementary component to the high flow performance air intake system for the performance driver. This is a necessary upgrade for anyone looking to address a critical area of engine reliability and efficiency, particularly on a component that is subjected to the most heat gain in the engine.

When combined with other modifications such as upgraded turbos, performance tuning or a better intake system, the AFE BladeRunner exhaust manifold will ensure that the energy in the exhaust gas is transferred in the most efficient and consistent manner.

A Foundation for Efficient Boost

AFE BladeRunner Exhaust Manifolds combine added structural integrity with vastly improved exhaust flow characteristics. These are not just replacement parts, but rather an all out upgrade to both the integrity of the material used and the internal geometry of the exhaust manifold.

A common topic with most diesel owners is increasing the efficiency of the turbo, and longevity of their diesel engine while under heavy demands. Improving exhaust manifold efficiency is an essential step. Improving exhaust manifold efficiency at the root of the exhaust system on a diesel engine will enhance turbo spool up time, maintain boost pressures for longer, and give more peace of mind while working in extremely hot conditions.

They are engineered not only to handle the stress of performance builds, but to elevate the efficiency of the entire turbo system from the very beginning of the exhaust cycle.