Looking to add more power and performance to your Ford Bronco or Bronco Raptor? In this post, we're breaking down three of the best intercooler upgrades available now at BuckleUpOffroad.com, and why they matter. Whether you're daily driving, off-roading, towing, or looking for a reliable performance boost, an intercooler upgrade is one of the easiest bolt-on mods you can do to keep intake temps low and power levels high. Cooler air equals denser oxygen, which means better combustion, more spark advance, and more consistent horsepower without pushing your engine too hard.
If you follow along on my YouTube channel, you know I’m currently running the COBB intercooler on my four-door 2.7L Bronco, lovingly known as Buttercup. This intercooler is a solid performer with a 53% increase in core volume and a 23% boost in cooling efficiency over stock. It’s cast aluminum, TIG-welded, and bolts directly to the OEM shutter shroud without the need for cutting or trimming—making it a favorite for those who want big gains with a clean, simple install. It fits both the Bronco and the Bronco Raptor and is 50-state legal, so it checks all the boxes for performance and compliance.
Next up is the Whipple Mega Cooler, and let me tell you—this thing is a beast. Designed for both the Bronco and Bronco Raptor, it offers a 58% increase in internal core volume, 144% more external fin surface area, and 12% less restriction compared to the factory intercooler. It’s made with a bar-and-plate TIG-welded design and features offset fins on both hot and cold sides to maximize airflow. On the dyno, it dropped intake temps by an impressive 32 degrees during back-to-back pulls. Even better, it’s 50-state legal and includes a new adaptive cruise control relocation bracket and an air duct to increase airflow. And here’s the exciting part—we’ve test-fitted it with Process West charge pipes, and it fits! That means we’re developing Stage 1 power packs for the Bronco Raptor, and if that’s something you’re excited about, be sure to hit the “notify me when available” button on the website so you’ll be first in line when they launch.
Finally, for those of you looking for a budget-friendly option made right here in the USA, check out the PLM HD Billet Intercooler. This one’s for Bronco owners only (not compatible with the Raptor), but it offers serious value. It’s designed to reduce heat soak, support turbocharger longevity, and bolts right up using factory hardware. The only catch? You’ll need to remove the factory air shutters to avoid contact with the core, but beyond that, installation is straightforward and performance is comparable to the COBB unit—without the bigger price tag.
Each of these intercoolers offers unique benefits depending on your build goals and budget. If you're serious about performance and keeping intake temps low, these upgrades are well worth the investment. Want to see them up close and hear how they stack up in the real world? Check out the full video on my Buckle Up Buttercup YouTube channel, where I walk through each option, share install tips, and give my honest thoughts from firsthand experience. As always, you can shop these intercoolers now at BuckleUpOffroad.com.
Until next time—Buckle Up Buttercup.
