THE NATURAL CHOICE
Bar-and-plate construction brings a much higher internal volume and improved thermal mass compared to tube-and-fin cores. The strength and heat dissipation advantages made it the natural choice.
PERFORMANCE INTERCOOLER
for the 2022+ FORD MAVERICK
Ford Performance (now newly rebranded to Ford Racing Parts) set out to develop an upgraded intercooler for the Maverick, they came to us, the world leader in performance cooling, to make it happen. Their goal was to create a solution that fit entirely within the stock mounting envelope, installed just like the factory unit, and delivered a significant improvement in cooling efficiency and airflow.
Ford's Project Goals
From the very beginning, both teams were aligned on the objectives. Ford Performance needed a dependable upgrade to support their performance package, and they wanted something that Maverick owners could install without making any permanent modifications. Those expectations shaped every stage of development, and the final design reflects a careful balance of OEM fitment and enthusiast-focused performance.
Analysis and Development
The development process began with Ford Performance supplying us with a factory intercooler and complete 3D vehicle models. These resources allowed us to examine the stock hardware in detail before ever placing a Maverick on a lift. The factory intercooler is a tube-and-fin unit measuring 25.2 inches wide, 5.55 inches tall, and 2.52 inches thick. Its nine-row layout and plastic crimped end tanks are completely adequate for a stock truck. However, once the owner starts adding power, towing heavier loads, or operating the truck in heat soak conditions, the original design begins to show its limits. Tube-and-fin cores shed heat quickly during light use, but they also heat soak rapidly when pushed harder. Plastic end tanks save cost and weight, but they’re not well-suited for sustained high boost. This analysis made the upgrade path clear. The Maverick platform needed a larger core, stronger construction, and smoother airflow management. It also needed to preserve every factory mounting point, sensor location, and hose connection.
We evaluated the available packaging space in the digital model and found that the Maverick allowed for a meaningful increase in overall size while still remaining within the OEM layout. Our engineers created a bar-and-plate design measuring 27.17 inches wide, 6.15 inches tall, and 3.35 inches thick. Bar-and-plate construction brings a much higher internal volume and improved thermal mass compared to tube-and-fin cores. It is heavier, but the strength and heat dissipation advantages made it the natural choice for this application. The change in dimensions created a core that is 58.8% larger than the stock unit and increased the fin surface area by 71.1%. Those increases happen entirely within the original space allowed by Ford, which means fitment remains as simple as removing the stock unit and installing the new one.
SolidWorks model of the computer simulated airflow path and Mishimoto end tanks.
The larger core required redesigned end tanks to fully utilize the increased volume. We used computer simulations to predict optimal flow paths and evaluate airflow distribution across all twelve rows of the new core. Even distribution prevents hotspots and maintains consistent cooling across the full width of the intercooler, especially during repeated back-to-back pulls where heat soak becomes a factor. This careful design ensures the turbo doesn’t have to work harder to maintain boost while maximizing the performance gains from the expanded core.
Rather than replicate the stock plastic design, we developed cast aluminum tanks and TIG welded them directly to the new core. This construction method eliminates the gasket found in the factory design. Gaskets are prone to drying and cracking over time, which can allow leakage, pressure loss, or outright failure. The welded aluminum construction also allows the intercooler to safely withstand significantly higher boost pressures. Construction strength was one of the key goals of Ford Performance, and the move from crimped plastic to welded aluminum represents a major leap forward in structural integrity.
Designed To Improve Charge Air Cooling And Efficiency.
Engineered by Mishimoto to meet Ford Performance standards, this performance intercooler offers a larger and more robust core without requiring any permanent modifications while maintaining stock fitment.
58.8% increase in core volume
compared to stock for superior cooling
39.6% reduction in peak temperature
over stock, a substantial improvement
Available Exclusively at Ford Racing Parts
Testing at Ford Performance HQ
Testing took place on a DynoJet 424x at Ford Performance’s headquarters in Dearborn, Michigan. Runs began only after the truck reached full operating temperature and each configuration was tested under the same environmental conditions. The first configuration was the stock intercooler with stock piping. The second used the Mishimoto intercooler while keeping the original piping in place. This provided a clean comparison that isolated the intercooler as the only variable. After the truck reached its operating window, multiple dyno runs were completed until consistent readings were achieved. The truck was idled between each run to maintain coolant temperature and prevent swings that could affect airflow or intercooler behavior. Both configurations also underwent back-to-back heat soak simulation runs to mirror real-world driving scenarios where long periods of full throttle quickly reveal the limits of a small intercooler.
INCREASE BOOST,
POWER, AND FUN
Featuring a TIG-welded construction and a durable bar-and-plate core, the intercooler is designed to handle higher boost pressures while maintaining long-term dependable reliability.
The temperature results were immediately noticeable. During stock testing, the peak outlet temperature reached 93.8 degrees Fahrenheit. After installing the Mishimoto intercooler, the peak outlet temperature dropped to 56.7 degrees. That’s a 39.6% reduction, which is a substantial improvement for a direct-fit factory replacement. This drop in temperature is largely influenced by the larger core volume and the more efficient bar-and-plate construction. The thicker core can absorb more heat without saturating, and the increased fin surface area helps reject heat more effectively. For a platform like the Maverick that relies heavily on consistent charge air temperatures for both performance and reliability, this improvement directly affects how the truck behaves under heavy load.
39.6% reduction in peak temperatures
20.1% in intercooler pressure drop
Pressure drop told a similar story. The stock intercooler created an average drop of 1.19 psi between the inlet and outlet. The Mishimoto core reduced that to 0.95 psi. That 20.1% reduction means the turbocharger works against less restriction. Lower restriction reduces turbo effort, decreases compressor outlet temps, and improves overall engine efficiency. Pressure drop often gets overlooked in casual discussions about intercoolers, but it plays a significant role in how responsive and consistent a turbocharged engine can be. Ford Performance took this metric seriously, and it became one of their key evaluation points in determining the suitability of the Mishimoto unit for the performance package.
Testing Results
By the end of testing, the intercooler met every objective that Ford Performance outlined. It stayed entirely within the OEM packaging space, it installed using all stock attachment points, it provided significant reductions in temperature and pressure drop, and it offered stronger construction capable of supporting higher boost targets. Most importantly, it created the cooling and efficiency overhead required to meet Ford Performance’s power goals.
Beyond supporting higher power levels, the upgraded intercooler maintains consistent boost pressure under heavy usage and demanding conditions. When cooling capacity becomes limited, the turbo must work harder to maintain boost levels, which robs the engine of power. The increased capacity of this intercooler prevents that scenario, ensuring the engine delivers its intended power whether during daily driving, towing, or repeated performance runs.
71.1% greater in
fin surface area
for cooler, denser air and stronger boost
20.1% reduction in
pressure drop
for more boost and better turbo efficiency under load
Available Exclusively at Ford Racing Parts
The intercooler will be offered both as a standalone upgrade and as an essential component of the Ford Performance Maverick package. For owners who want improved durability and performance, even without the full package, it offers a direct-fit solution that benefits daily driving, towing, and future modifications.
This project has shown just how much can be accomplished through a focused collaboration. Ford Performance set the direction, provided resources, and supported extensive testing, while our team delivered a design that met their requirements and advanced their program goals. We are proud to see the Mishimoto Performance Intercooler become an official part of the Ford Performance lineup and are excited to put it in the hands of Maverick owners who want a dependable, efficient upgrade that preserves factory fitment while delivering real performance gains. Both our team and Ford Performance are thrilled with the result, and we couldn’t be more excited to see the Mishimoto intercooler unlock the full potential of the Maverick for drivers everywhere.
THE PROJECT’S BEEN GREAT
Mishimoto had the right engineering disciplines, all the timing was met or exceeded, and to this point has been a success in our minds in terms of support and quality.
RON EWERT, Ford Performance Engineer
In the Press
Car and Driver
Autoweek
Sema 2025 with TFLnow
The Driver
Why Mishimoto?
Mishimoto, the world leader in performance cooling products, was created for automotive enthusiasts by automotive enthusiasts. Established in 2005, we have two decades of experience in working toward our goal of providing superior cooling system upgrades.
FITMENT
All Mishimoto products are carefully designed for a clean, direct-stock fit for an easy installation.
QUALITY
All our products are rigorously tested to ensure the quality of our data. Visit our Engineering Blog for more information.
APPEARANCE
With an array of product finishes and colors that will add style, your engine will look just as great as it performs.
WARRANTY
Every product is covered by our Lifetime Warranty which includes accident protection for cars and trucks.