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Long Travel Super Duty Upgrade: Carli Suspension Upgrade Helps Work and Play

In stock trim, the F-250 4×4 is a good work truck. If you get one with the factory ­­­­­­ FX4 package, it brings you skid plates for the transfer case, fuel tank, Hill Descent Control and Rancho shocks.  However, it’s still a work truck and rides like a heavy-service vehicle on pavement and off.

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Seen here is a stock F-250 (top). Here's the same truck with a Carli Suspension Dominator 3.0 kit (bottom).
Seen here is a stock F-250 (top). Here’s the same truck with a Carli Suspension Dominator 3.0 kit (bottom).

A Carli Suspension lift doesn’t only raise the stance of your rig; it improves the ride under all driving conditions. The smoother ride and bolder look doesn’t sacrifice any of the truck’s work capacity: It just makes it more fun and comfortable to drive. Carli offers both components and full kits. The two basic lift heights are 2.5-inch and 4.5-inch. We stopped in and followed along while the Carli crew upgraded a new F-250 with the Dominator 3.0/4.5-inch lift. This kit has everything and a bag of tricks; installing it takes some time, but the end result is a truck that rides more like a sedan than any factory rig, and it eats up street bumps with ease.

Follow along, and we’ll show you the highlights of the install and some shots of the trucks capabilities after the Carli kit gets installed. DW

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1. Here you see the front components of the Ford F-250 lift in these pages. This is the full Dominator 3.0, 4.5-inch lift setup. The front upgrade included new King remote reservoir shocks, longer springs, new front coils, coil buckets and much more.
1. Here you see the front components of the Ford F-250 lift in these pages. This is the full Dominator 3.0, 4.5-inch lift setup. The front upgrade included new King remote reservoir shocks, longer springs, new front coils, coil buckets and much more.
2. Installation at the front begins with raising the truck and then removing the stock components. Here you see the front upper coil bucket and shock mount brackets being removed. The OEM rivets must be cut off; an air chisel works best for this.
2. Installation at the front begins with raising the truck and then removing the stock components. Here you see the front upper coil bucket and shock mount brackets being removed. The OEM rivets must be cut off; an air chisel works best for this.
3. Note the OEM upper spring and shock bracket (L) compared to the new Carli unit. While similar in look, the Carli bracket allows the use of longer coils and shocks.
3. Note the OEM upper spring and shock bracket (L) compared to the new Carli unit. While similar in look, the Carli bracket allows the use of longer coils and shocks.
4. The OEM front spring and shock (L) are seen here, compared to the longer Carli springs and remote reservoir shocks.
4. The OEM front spring and shock (L) are seen here, compared to the longer Carli springs and remote reservoir shocks.
5. Once the OEM upper spring and shock bracket is removed, the new Carli bracket bolts into the same holes the stock rivets were in.
5. Once the OEM upper spring and shock bracket is removed, the new Carli bracket bolts into the same holes the stock rivets were in.
6. Longer, braided stainless steel brake lines are installed and then the new, longer front coils are put in place.
6. Longer, braided stainless steel brake lines are installed and then the new, longer front coils are put in place.
7. With the longer coils in place, the front King remote reservoir shocks are installed. This combination will ride smoother and have more travel, offering your rig more tire and trail clearance.
7. With the longer coils in place, the front King remote reservoir shocks are installed. This combination will ride smoother and have more travel, offering your rig more tire and trail clearance.
8. Before the new Carli front suspension arms can be installed, the drop down bracket must be installed on the frame.
8. Before the new Carli front suspension arms can be installed, the drop down bracket must be installed on the frame.
9. Here you see the completed front installation of the Carli 3.0 Dominator kit on our Ford F-250. It’s a clean, rugged and functional system that is far superior to the stock setup for ride quality, height and added travel for rutted roads and trail.
9. Here you see the completed front installation of the Carli 3.0 Dominator kit on our Ford F-250. It’s a clean, rugged and functional system that is far superior to the stock setup for ride quality, height and added travel for rutted roads and trail.
10. Here is a comparison of the OEM rear spring and the new Deaver springs in the Carli Kit. The new rear leaf springs are a multi-leaf design that rides better under virtually all conditions.
10. Here is a comparison of the OEM rear spring and the new Deaver springs in the Carli Kit. The new rear leaf springs are a multi-leaf design that rides better under virtually all conditions.
11. The rear springs are heavy, and it is best to have help when removing the OEM pack, especially when reinstalling the new and thicker pack in the Carli kit.
11. The rear springs are heavy, and it is best to have help when removing the OEM pack, especially when reinstalling the new and thicker pack in the Carli kit.
12. As with the front, the stock shocks are replacements with larger and longer coil-over shocks from King. Carli has their shocks custom made to fit each application, after hours of tuning on a wide range of driving surfaces. This ensures the best ride possible.
12. As with the front, the stock shocks are replacements with larger and longer coil-over shocks from King. Carli has their shocks custom made to fit each application, after hours of tuning on a wide range of driving surfaces. This ensures the best ride possible.
13. Here you see the new Carli rear shock mount (L) compared to the OEM mount. The OEM mount must be cut off the frame since it is riveted.
13. Here you see the new Carli rear shock mount (L) compared to the OEM mount. The OEM mount must be cut off the frame since it is riveted.
14. Seen here is one of the two new rear shock mounts, now bolted to the frame using the OEM brackets’ rivet holes.
14. Seen here is one of the two new rear shock mounts, now bolted to the frame using the OEM brackets’ rivet holes.
15. With the new the new remote reservoir shock installed, the rear air bags can be installed. These air bags add the extra carry capacity needed to level the truck at max OEM load. This is an upgrade to the basic suspension kit, but well worth it on any truck that often carries heavy or tows with big trailers.
15. With the new the new remote reservoir shock installed, the rear air bags can be installed. These air bags add the extra carry capacity needed to level the truck at max OEM load. This is an upgrade to the basic suspension kit, but well worth it on any truck that often carries heavy or tows with big trailers.
16. This view shows the flexibility of the Carli suspension on the Ford F-250 4x4.
16. This view shows the flexibility of the Carli suspension on the Ford F-250 4×4.
17. On the opposite side, you can see just how much “up-travel” the Carl kit offers. This 37-inch tall tire is stuffed into the wheel opening, with just enough clearance to prevent grabbing the wheel openings. This size tire won’t even fit on the truck, with the OEM suspension; here it fits even with the suspension flexed out.
17. On the opposite side, you can see just how much “up-travel” the Carli kit offers. This 37-inch tall tire is stuffed into the wheel opening, with just enough clearance to prevent grabbing the wheel openings. This size tire won’t even fit on the truck, with the OEM suspension; here it fits even with the suspension flexed out.
18. This Toyo Open Country AT 37x13.5R20LT fills the rear wheel opening and looks cool mounted on a Fuel 20x9 Octane wheel. Here the suspension on this side is against the rear bump stops. At normal ride height, there’s even more clearance around this huge tire.
18. This Toyo Open Country AT 37×13.5R20LT fills the rear wheel opening and looks cool mounted on a Fuel Offroad 20×9 Octane wheel. Here the suspension on this side is against the rear bump stops. At normal ride height, there’s even more clearance around this huge tire.
SOURCES:

Carli Suspension . 714-523-2798 . Thecarlisuspension.com

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