05-07 FORD F250/F350 4.5" COILOVER BYPASS 2.5 SYSTEM, BASE, DIESEL

Carli 4.5” Coilover Bypass Suspension System

One of our most capable off-road systems, the Coilover Bypass delivers unmatched control with a street ride similar to the Coilover and Pintop kits but with seemingly no bottom. This setup features King 2.5” Front Coilovers, 10” Stroke 2-Tube Front Bypasses, and 12” Stroke Rear 3-Tube Bypasses with oversized rebound tubes. It’s also height-adjustable by ~1” to compensate for large bumpers or winches.

Bypass Shock Technology

Bypass shocks feature external tubes with one-way check valves that allow users to fine-tune compression and rebound. At ride height, bypass tubes provide supple comfort by routing fluid around the piston. On big hits, ports close, forcing fluid through valving to increase resistance— acting like an internal bump stop.

On rebound, oversized tubes allow rapid shaft extension to maintain traction. As the piston nears full extension, the tubes close, and rebound valving slows the shaft to prevent harsh top-out. Larger shock diameters, more tubes, and bigger zones all translate to increased adjustability, control, and capability.

Carli-Specific King Shocks

• Custom Carli pistons designed for heavy-duty trucks
• Precision-tuned for seat-of-the-pants performance
• 17-4 Stainless shafts – corrosion resistant, no coating to wear off
• King oil rated to -55°F for extreme conditions
• Plated steel shock bodies (wrap with 3M protective film for long-term exposure)
• Fully rebuildable for long-term service

Front Suspension

• Sits 4.5” higher in the front
• Carli Coilover Conversion Brackets for coilover fitment
• Radius Arm Drop Brackets – reset pivot point, maintain linear travel
• Sway Bar Links or Drop Brackets – restore sway bar geometry
• Bump Stop Drops – protect shocks from over-compression
• Adjustable Track Bar – centers front axle
• Stainless Brake Lines – stronger feel + added travel
• Caster Shims – improve steering response

Rear Suspension

The rear is equipped with a Full Progressive Spring Pack that eliminates the need for blocks. This setup increases travel and minimizes wheel hop/axle wrap, at the cost of about 15% less load capacity compared to a stock F-250.

Recommended Upgrades

• Differential Guard – axle protection
• High Mount Steering Stabilizer – improved steering control
• Fabricated Radius Arms – strength + limit strap mounting
• Limit Straps – protect shocks at full droop
• Roll Cage – advised for aggressive off-road use

Ride & Adjustability

Being bypass-equipped, expect audible clicking as check valves open and close. Carli ships these shocks with a wide-open rebound and neutral compression, but customers can adjust tubes for more comfort or more control depending on conditions.

Wheel & Tire Fitment

• Factory wheels with oversized tires: NOT recommended (interference with brake lines, sway bar, and radius arm)
• Factory wheels with factory tires: safe, no issues
• Recommended wheels: 17”–18” diameter, up to 9” wide
• Backspacing: 4.5”–5.0”
• Tires: 37” E-Rated (ideal for compliance and support)
• More sidewall = better small bump absorption
• Larger wheel diameters = firmer ride