CS-FLVL-CO25-BYP-11 | Carli Suspension Carli Tuned King 2.5" Front & Rear 2.5" Lift Coilovers System For Ford F-250/F-350 4WD | 2011-2016 | Diesel

Providing height adjustability, dual front shocks and ultimate bottom-out resistance, the Coilover Bypass kit is the best option for the avid off-roader. 2.5″ Coilover and 2-Tube, 2.5″ bypasses adorn the front wheel well, while 3-Tube Rear Bypasses and Full Progressive Leaf Springs round off the rear. This system maintains great on-road manners and is the most off-road capable of our 2.5″ lift lineup.

Front Lift: 2.5-35″ / Front Travel: 8″ /  Rear Lift: 0-2" / Rear Travel: 13″ / Shock Diameter: 2.5" / Tire Fitment: 35″ x 12.5″

A “Base Kit” SKU must be accompanied by the SKU of a Leaf Spring option to form a complete 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, 8” 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 2.5” higher in the front and have more wheel travel thanks to the Coilovers. Stainless Brake Lines and an Adjustable Track Bar round off the front end geometry correction while Caster Shims improve on the stock handling. The rear is outfitted with a block eliminating Full Progressive Spring Pack lifting it 2” requiring no block to achieve proper ride height in the rear. The result is extended travel and a softer ride while wheel hop/axle wrap are minimized at the cost of 15% less load capacity than a stock F250.

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).

Wheel and Tire:  On our 2.5” Ford Bypass Equipped Systems, we recommend 17”-18” wheels, no more than 9” wide with 5” of backspacing with Carli Fabricated Radius Arms. Tires, 37×12.5” will fit with some trimming; 35” will likely fit without trimming. The more rubber, the better the small bump compliance will be at proper inflation pressures. The ride will firm up as you go larger in wheel diameter. For more details, see our article on wheel and tire selection and tire pressures:

Tires and Wheels: How Do They Affect My Ride?

Customization Information

Rear Leaf Spring Options

*REQUIRED*

11-16 FORD F250/350 4X4 FULL PROGRESSIVE LEAF SPRING KIT - 1" LIFT

SKU: CS-FFSP-LVL-11
- Block eliminating, Full Progressive Spring Pack
- Includes new U-Bolts and Rear Bump Stop Drops
- Provides a 1/2", rear high stance to Carli Leveling Suspension Systems
- Fitment: 2011-2016 F250/350 4x4, Diesel - 3.5" Axle Tube

11-16 FORD F250/350 4X4 HEAVY DUTY FULL PROGRESSIVE LEAF SPRING KIT - 1" LIFT

SKU: CS-FFSP-LVL-11-HD
- Block eliminating, Full Progressive Spring Pack
- Heavy Duty Full Replacement Leaf Springs designed for those with constant 1,000lbs in the bed
- Includes new U-Bolts and Rear Bump Stop Drops
- Provides a 1", rear high stance on Matching 2.5" Leveling Suspension Systems
- 37" Tire Fitment
- Fitment: 2011-2016 F250/350 4x4, 3.5" Axle Tube

Torsion Sway Bar

*Optional*

For everyone that’s not loaded to the GVWR daily, the Carli Torsion Sway Bar provides the final link lightening the last spring on the truck maximizing the ride quality of the Super Duty Platform. Keeping your factory bar limits comfort, removing it completely makes for questionable control when hauling or emergency maneuvering. After several revisions and years in development, the Carli Torsion Sway Bar Splits the Difference perfectly allowing a small amount of differentiation side to side before progressively engaging to add the needed control as leverage is applied. Rip corners in the dirt with surgical precision knowing there’s exactly enough rate to hold the body steady while cutting your line through the dirt. Hit the tarmac and enjoy the benefit of the lighter rate bar cruising around town with it’s on-road feel reminiscent of an independent front suspension – no more chassis reverberation on small bumps and let the suspension dance in the level cab while hitting off-camber driveways.

11-16 FORD F250/350 4X4 TORSION SWAY BAR KIT - 2.5" LIFT

SKU: CS-FTSB-LVL-11
- Direct Fitment to Carli Leveling Lifts
- Replaces Immobile Factory Sway Bar with Custom Torsion Bar
- Huge Ride Quality Improvement

Leaf Spring Shackle

*OPTIONAL*

Much of the jarring ride of the Super Duty rear can be attributed to the factory vulcanized bushings in the leaf spring pack and shackle. The factory shackle is very strong BUT the design is not conducive to a smooth ride. The Carli shackle is constructed of 1/4″ American cold-rolled steel. The mid-length gusset ensures no deflection while the serviceable bushings offer a far superior ride to the bind of the factory bushings.

05-23 FORD F350/350 4X4 FABRICATED LEAF SPRING SHACKLE

SKU: CS-FSHACKLE-11
- Greasable and Rebuildable
- Far Better Ride than Factory Shackle
- 1/4" Steel Construction
- Fits Factory and Carli Springs

Radius Arm Options

*OPTIONAL*

Icing on the cake, these arms add Additional Tire Clearance, Limit Strap Protection for your Front Shocks, 1/4" Boxed Steel Constructions, Serviceable 17-4 Stainless Spherical Bearings and Adjustable Caster Correction up to 3.5° over stock specs to leave Death-Wobble in the rear-view.

05-22 FORD F250/350 4X4 FABRICATED RADIUS ARMS - 2.5"/3.5" LIFT

SKU: CS-FARA-LVL-05
- 0.5°-2.5° of adjustable Caster correction
- 3/16 Construction, Fully Internal Gusseted with 1/2" Additional Tire Clearance
- 12" Limit Straps Kit Included
- 17-4 Stainless Spherical Joint for longevity and bind free Cycling

High Mount Steering Stabilizer

*OPTIONAL*

Bolt in replacement for the factory stabilizer. Adjustable from 70-200 psi to run neutral (no directional influence at 70psi) or at 200psi to counter the right-hand pull inherent to tires like Toyo Mud Terrains.

08-16 FORD F250/350 4X4 HIGH MOUNT STEERING STABILIZER - STAINLESS STEEL - 2.5" & 4.5" LIFT

SKU: CS-FHMSS-08
- Inside the Carli Stainless Stabilizer
- Bolt in Replacement for OEM Stabilizer
- Fitment: 2008-2016 F250/350 4x4
- Works on levelled and lifted trucks ONLY
- WILL NOT work with Dropped Pitman Arms

Low Mount Steering Stabilizer

*OPTIONAL*

Bolt in steering stabilizer which compliments a Carli, or factory, high mount stabilizer. Adjustable from 70-200 psi to run neutral (no directional influence at 70psi) or at 200psi to counter the left-hand pull inherent to tires like Nitto Trail Grapplers. Run in conjunction with the Carli High Mount for the ultimate Dual, Opposing Steering Stabilizer combination that's infinitely adjustable.

05-22 FORD F250/350 4X4 LOW MOUNT STEERING STABILIZER KIT - WITH DIFFERENTIAL GUARD

SKU: CS-FLMSS-05
- Custom Valved for Larger Tires, Adjustable Nitrogen Pressure
- Includes Differential Guard and Clamp
- Combines with High-Mount Stabilizer for Opposing Setup
- Optimized for Carli 2.5"-5.5" Systems