Regarding your 7-10% rumor—I doubt that Raptor sales have/will ever be more than a small volume niche seller compared to U.S. or global F-150 sales. We are talking units of F-150 sales volume. High prices will always keep the sales volume of the Raptor (and niche cars/trucks by all manufacturers) very low as a % of units.
The luxury perception/off road image, and of course profit margins of course are high—but the profit margins are also high on F-150 Limited, King Ranch, and the high end trucks by most OEMs. I’d guess that the traditional loaded F-150s outsell the Raptor by a good margin and always will—thus making the Raptor a niche/halo in an overall category.
Top of mind, a handful of advantages of IRS include: improved ride quality/comfort, handling both on/off pavement, higher speeds off-road (to match the “desert runner” marketing). IRS would also differentiate the Raptor.
When Ford slapped the IRS on the SVT Mustang, they reverted back to solid axle. It was great in theory, only good in practice, and had several drawbacks on the street, drag strip and road course. I’m sure that things have advanced now, but an IRS on a Raptor would need to be orders of magnitude stronger than the Mustang unit.
If road ride is the target then Ford would be wise to consider IRS for the limited/platinum platform.
I think Ford made a solid effort to produce the Raptor in volume so that it wasn’t so much of a niche truck as a serious off road option that was exclusive, but attainable. The new interior goes a long way to address shortcomings in the marketplace, honestly, I don’t find the interior lacking. I think the massaging seats from the other models of Ford/Lincoln are an obvious choice to upgrade the truck.
Suspension is like Alchemy; part art, part science, part supernatural. When you get it right, don’t screw with it. Look at motorcycles - for years - decades, someone has been trying to come up with a front suspension option other than forks and springs; The most successful has been bmw’s tele lever / para lever. You don’t see any of them winning races. They’re big, heavy, lack adjustability and precision, and road feel is significantly compromised. IRS would be one of those mods that would need to be spec’d by engineers as a take it or leave it option, because if some cost cutter comes in and undercuts the tested platform it will have serious negative consequences for the way the truck performs, which the press will pick up on as well as end users.
This would add a lot of cost to the truck and require a lot of engineering testing. The truck would have to perform better in several areas without “giving up” anything in other areas.
I see a lot of potential cost add, for a relatively low return on investment in the Raptor platform, if any.