Carli 4.5" Super Duty Coilover-Bypass 2.5 Suspension System

Stainless Shock Shafts Are Now Standard!

Super Duty King Coilover-Bypass 2.5 Suspension System

This suspension system will be the last system you will buy for your Ford truck. This is not a "lift kit"`. It is a true suspension system.

This is one of our most capable off-road systems. Similar in street ride to the Coilover and Pintop kit with seemingly no bottom, we spec’d this system with King 2.5” Front Coilovers, 10” Stroke 2-Tube Front Bypasses, 12” Stroke Rear 3-Tube Bypass with an oversized rebound tube. This system is also height adjustable approximately 1” to compensate for large bumpers/winches.

For those unfamiliar, a bypass shock has external tubes with one-way check valves that are fully adjustable to allow users to tailor the amount of fluid that bypasses the piston/valving on either the compression or rebound stroke within the effective range of the bypass tube. Typically, there will be a tube surrounding the compression zone at ride height that will allow fluid to freely move around the piston giving a supple ride. Once a large hit is encountered, the piston will move upward closing off the port, thereby forcing all fluid through the valving which substantially increases the shock’s resistance in this secondary zone. This acts as an internal bump-stop of sorts and gives tunable progression to the shock making it the perfect dual purpose setup.

Conversely, on the rebound side, we normally spec tubes that are oversized and deep in the travel stroke to allow a high volume of oil to bypass ensuring the shock shaft comes out quick enough to maintain contact with the ground (doesn’t get hung-up in the bump-zone after a large hit). As the shock extends and closes off the rebound tube, all the valving on the rebound side engages to slow the shaft as it reaches maximum extension, top-out. Simply put, the larger the shock diameter, the more capable the setup; the more tubes and “zones”, the more adjustability; the larger the tubes, the more fluid can flow around the piston and the more valving you can run to increase the stopping power in the “bump-stop” or “top-out” zone.

The Coilover/Bypass system boasts Carli specific, blueprinted, King 2.5” shocks on all four corners. In an effort to provide customers with the best product, we designed a custom piston to determine proper base flow rates to ensure the shock works well in the heavy duty truck platform; we then tuned the shocks around the custom pistons based on the only thing that matters to us, seat-of-the-pants feel. We round off ALL our King shocks with shafts machined and polished from a solid piece of 17-4 Stainless. Unlike King’s standard shafts, there is no coating to wear off, weather can’t hurt them and if there is a small chip, you can round the edges with emery cloth to ensure the seal housing isn’t damaged as they’re not brittle like the stock, hardened shafts. The shocks are finished with King oil good to -55° F. Note that all King shocks are built with a plated steel body. If subjected to inclement weather for extended periods, we recommend wrapping your shocks in 3M to provide a moisture barrier that’s replaceable.

The truck will sit 4.5” higher in the front and have more wheel travel thanks to the coilover that mounts in the Carli Coilover Conversion Bracket. Radius Arm Drop Brackets reset the pivot point and keep the travel linear for the best ride while Sway Bar Links or Drop Brackets reset the sway bar engagement point. While Bump Stop Drops protect the shocks from over-compressing, the Adjustable Track Bar centers the front axle and Stainless Brake Lines firm up braking and ensure there is enough line for the newfound travel. To round off the front end, we include Caster Shims to tighten the steering.

The rear is outfitted with a Full Progressive Spring Pack requiring no block to achieve proper ride height; thus, travel is extended and wheel hop/axle wrap minimized at the cost of 15% less load capacity than a stock F250. The Coilover-Bypass is an Off-Road oriented system; thus, we recommend the purchase of a Differential Guard for axle protection, High Mount Steering Stabilizer for steering control and Fabricated Radius Arms for strength and Limit Strap mounting. At this level of suspension, a roll cage is also recommended if the system will be used to its full potential.

Being bypass equipped, customers can expect to hear clicking from the opening and closing of the check valves in the external tubes of the shocks. On the bright side, the suspension is tuned by Carli but fully adjustable to the customer’s preference. Customers can turn tubes for more float and ride comfort or engage more valving for better control and off-road performance. From Carli, these shocks are setup with a wide open rebound and neutral compression (our recommended, all around specification).

Contact us about custom options like front and/or rear bypass options as well as custom shock finishes.

Accept Nothing Less...

This system utilizes King Off Road Racing Shocks and their premier coil-over race technology. You'll find these same shocks (in longer travel specs) on race vehicles from Barstow to Cabo. We chose to implement a single rate linear spring that allows 0-2 inches of ride height adjustment.

Features:

• Superior Ride Quality
• Very Controlled Off Road
• Increased Cornering Capability
• Reducing and/or Eliminating Body Roll
• Tighter street feel Driving Characteristics, Increased Suspension Response
• Steering geometry is all within OEM specs, no additional components are necessary
• Reduces F-250 payload by 15%. Long Travel Airbags can be added to 4.5" lift springs to achieve F350 SRW capacity.

Fitment Guide:

• CS-F45-CO25-BYP-11 | 11-16 F250 / F350 4x4 (Old Part Number: CS-FORDCOS-BYP-11)
• CS-F45-CO25-BYP-08 | 08-10 F250 / F350 4x4 (Old Part Number: CS-FORDCOS-BYP-08)
• CS-F45-CO25-BYP-05 | 05-07 F250 / F350 4x4 (Old Part Number: CS-FORDCOS-BYP-05)

Components:

• KING 2.5"x10" Custom Front Coil Over Shocks
• KING 2.5"x10" Custom Bypass Front Shocks
• KING 2.5"x12" Custom Bypass Rear Shocks
• 17-4 Stainless Steel Shock Shafts
• Coil Over Mounting Kit
• Radius Arm Drop Bracket Kit with Dimple Die Cross Member
• Sway Bar Endlinks (2011+ kit uses sway bar drop brackets instead)
• Adjustable Track Bar
• Full Progressive Leaf Springs
• Bumpstop Drops Front and Rear
• Extended Braided Brakelines

Altered Vehicle Characteristics:

• 4.5" of Lift on the Front
• 2.5" of Lift on the Rear
• Vehicle is "Leveled"
• 10.0" of Front Wheel Travel
• 12.0" of Rear Wheel Travel

System Notes:

• Wheels - Carli Recommends a 17"-18" Wheel, no more than 9" wide with 5" of Backspacing on 4.5" Lift Systems.
• Tires - 37", E-Rated Tire Fitment is Recommended. Recommended unloaded Tire Pressure 45F/40R.
• Recommended Configuration - Carli 4.5" Systems are Designed and Tested on Vehicles with 17"-18" Wheels with 37", E-Rated Tires. Stock wheels and tires or running a larger wheel diameter will result in a stiffer ride.
• Leaf Springs - Full Replacement Leaf Spring Option Requires NO BLOCKS to achieve level Stance.

Full Leaf Notes:

Choosing the full leafs will offer a better street ride, further decrease wheel hop, and eliminate the need for a rear lift block altogether.

Full Leaf Shipping Info - If you are choosing the full leaf upgrade we will need you to provide an address that accepts freight truck deliveries as the kit will ship on a pallet. Please contact us if you have any questions about shipping.

05-10 Sway Bar Options

• CS-FEL-05 OR CS-FEL-08 - Sway Bar End Links
  • Easy Bolt-On
  • Heavy Wall Material
  • Excellent Articulation
  • Rebuildable
  • Ford Extended End Link for 4.5" Suspension System

..

2011-2016 Sway Bar Options

• CS-SBD - Sway Bar Drop
  • Drops entire sway bar brackets for proper geometry
  • 3/16" Steel Plate gusseted for utmost strength
  • Black Powdercoat
  • Grade 8 Hardware

Rear Lift Options

Although it is possible to order this kit without this option, it is HIGHLY recommended that you do choose this options in order for this kit to perform as expected.

• CS-FFSP-(08, 11) - Full Progressive Leaf Spring Pack
  • Block eliminating, Full Progressive Spring Pack
  • Includes new U-Bolts and Rear Bump Stop Drops
  • Provides a 1", rear high stance on Matching 2.5" Leveling Suspension Systems
  • 35" Tire Fitment

Radius Arm Option

• CS-FFRA-05 - Radius Arms for 4.5in Lifts
  • For 4.5" Systems
  • 1° of Caster correction engineered into arm
  • Internal Gusseting
  • Limit Straps Included
  • 1/2" Additional Tire Clearance
  • Huge Johnny Joint at Frame Connection for longevity and bind free Cycling

Carrier Bearing Drop

• CS-CARRIERDROP-F - Carrier Bearing Drop
  • Carrier Bearing Drop for 4.5" Suspension Systems with 2-piece rear driveshaft
  • 4 SHIMS, 2 Bolts 1/2" x 2", 2 nuts, 4 washers.
  • Fitment: 2005-2016

Shipping Info - This system ships on a pallet so we will need you to provide an address that accepts freight truck deliveries. Let us know if you need any help with this.