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I've posted parts of this multiple times and it seems to be valuable and warrants its own thread. I'll probably edit the OP to keep up with comments/changes/corrections. Lets keep this to functional/performance and cosmetic, things like "different wiring harnesses" don't belong IMHO.
** Are present on some non-Raptor years/trims/options packages
- Drive train
- 3.0 engine with more power and torque (418 hp/ 440 ftlb)
- 37" BFG K02 tires
- Larger/stronger F&R axles (Dana 44/50)*
- Larger/stronger inner and outer tie rods (? might be same as HOSS 3.0 rigs)
- Larger/stronger CVs and steering knuckles*
- Beefed up transfer case clutches
- Anti-lag turbo system (in Baja Mode)
- Larger/stronger F&R driveshafts
- Larger brakes (calipers and rotors)
- True dual exhaust system
- Larger lug bolts (14mm vs 12mm)
- Frame/Body/Suspension
- Internally reinforced frame (50% stiffer)
- Rear carbon fiber cross brace
- Larger/stronger suspension arms
- Fox 3.1 Live-Valve internal-bypass shocks
- More suspension travel F&R (13"/14")
- Significantly wider track (+8.6")
- Improved approach, departure and break over angles (47.2°, 30.8°, 40.5°)
- Increased tire clearance
- Disconnecting front sway bar**
- More robust and more coverage for underbody skid plates
- Increased water fording depth (37")
- Stronger and reinforced hitch adapter
- Interior
- Fully digital instrument cluster**
- Larger center screen**
- Magnesium paddle shifters
- Substantially better seats
- Other
- Transmission cooler
- Larger/stronger HOSS 4.0 steering rack (? might be same as HOSS 3.0 today)
- Greater towing capacity (4500 lb)
- Larger radiator fan
- Adjustable exhaust modes (Quiet, Normal, Sport, Baja)
- Adjustable steering (Normal, Sport, Comfort, Off-Road)
- Hood struts
- Stronger rear tire carrier
- Fog and driving lights in front bumper pockets
- Amber grill marker lights ("Raptor Lights")
- Amber front and red rear "width warning" lights in the side mirrors
- Cosmetic
- Different fenders with larger fender flares
- Different hood cowl with functional cooling
- Signature headlights with amber DRLs
- FORD logo grill
- Unique Raptor taillights
** Are present on some non-Raptor years/trims/options packages
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