Thursday, June 30, 2016

Early Summer 2016

Summer has arrived more quickly than expected and we have been very busy! Here are some of our favorite customer rigs:

Here is Mike's 5.9 Mega featuring Carli's first production 3" Long Arm Unchained System. Carli installed the system on this truck and we did some minor steering tweaks.

This brand new 2500 is sporting a Carli Commuter 2014+ system, Method Grid Titanium wheels, and 37" Toyo R/T's.

We dropped a Revmax 550 into this Mega sporting a Carli Suspension Unchained 6" system, Trail Ready beadlocks, and 37" Toyo R/T's.

This 2014 3500 is now rocking a Carli Suspension Back Country system, custom black powder coated Method Standards with OMF rings, and 37" Toyo MT's.

This new 2500 is rocking a Carli Pintop 2.5 system, Trail Ready beadlocks, 37" Toyo R/T's, and a Thuren Fabrication front bumper.

This 2015 Ram 2500 is sporting a Thuren Fabrication Fox 2.0 IFP Leveling Kit with 20" Fuel Trophy wheels and 35" BFG KO2's.

This 2011 F250 features a Carli 4.5" Back Country system with full progressive rear leaf springs, custom machined 22x12 wheels with 5.75" backspacing, and 37" Toyo MT's.

This 2500 features a Thuren Fox 2.0 IFP Leveling Kit, Fuel Pump wheels, and 35" BFG KO2's.

This 2016 Ram 3500 features a Carli Back Country system with 35" Toyo ATII's on the factory 20" wheels.

For more information on the Carli Suspension systems listed on this page, click here. For more information on the Thuren Fabrication systems, click here.

Thursday, May 26, 2016

Ball Joint Installation Tutorial

One of our most popular items is Carli's Extreme Duty Ball Joint set. We put together an instructional video to help when installing Carli ball joints on your Dodge 2500/3500. We hope this helps make the whole process that much easier! If you have any additional questions or comments, feel free to let us know!

Thursday, May 5, 2016

Spring 2016 Builds

This Spring has brought us some incredible builds as well as some nice updates to past projects. Here are some of our favorites:

James's Carli Performance 2.5 6" Mega cab turned out great with the addition of a Thuren Fabrication bumper, 37" Toyo Open Country R/T's, and more!

2013 2500 with a Carli Suspension Back Country 2.0, Carli High Clearance Control Arms, Carli Full Progressive Leaf Springs, 18" Method NV's, and 37x13.5x17 Toyo MT's

2015 3500 with Carli Pintop 2.5, Method NV 18", and Toyo 37" R/T's.

2014+ 2500 Mega Cab with Carli Back Country 2.0, 18" Method NV, and 37" Toyo R/T

2013+ 3500 Mega Cab with Carli Commuter 2.0, AEV Salta wheels. and 35" Toyo MT

2011 Ram featuring a Carli Unchained system (3" height), 17" Method Double Standards, and 37" Toyo Open Country MT

New 2500 with Carli Commuter 2.0, 18" Method NV wheels, and 37" Toyo MT

2012 with 6" Carli Pintop 2,5 System, 17" Method Standards, and 37" Toyo MT

2015 Ram 2500 featuring Carli Pintop 2.5, 20" Walker Evans Racing wheels, and 37" Toyo R/T

2016 Mega 2500 featuring Carli Pintop 2.5, 17" Trail Ready beadlocks, and 37x12.5x17 Toyo R/T

Alaskan Ford Super Duty featuring a 4.5" Carli Back Country 2.0, 17" Methods, and 37" Toyo MT

Thursday, March 3, 2016

February Trucks

February has come and gone and we have a lot of exciting builds to show off!

Here is a customer's 2013 Ram 2500 featuring a Carli Commuter 2.0 system, Carli High Clearance Control Arms, 18" Method Double Standards (+18 offset), and 37" Toyo Open Country MT tires.

Here is a 2016 Ram 2500 featuring a Çarli Back Country 2.0 system, 17" Trail Ready Simulated Beadlocks, and 35" Toyo Open Country R/T tires.

This 2015 F250 features a Carli Leveling Kit 17" Method NV's, and Toyo Open Country ATII's.

This 2016 Mega Cab 2500 features a Carli Commuter 2.0 system, factory 20's and 35" Nitto Trail Grappler MT tires.

This 2015 Mega Cab features Thuren front and rear springs, Fox 2.0 shocks front and rear, 18" Method NV's, and 37" Toyo R/T's.

This 2015 Ram 2500 features a Thuren Fox IFP Leveling Kit, 18" XD Series wheels, and 35" Toyo Open Country MT tires.

This 2013 F250 features a Carli Pintop 2.5 Leveling System with Carli Full Progressive Rear Leaf Springs.

This 2015 F250 features a Carli Back Country 4.5" system, Method Mesh wheels, and Toyo MT 35" tires.

This 2015 F350 features a Carli Back Country 4.5" system, 18" Fuel wheels, and 37x13x5x18 Toyo MT tires.

This 2012 Mega Cab features a Carli Pintop 2.5 system, a Carli Torsion Sway Bar, and Carli Full Progressive Rear Leaf Springs.

More updates coming soon!

Wednesday, February 17, 2016

Synergy's 1994-2002 Dodge 2500/3500 HD Steering Preview

After having worked with Synergy's 2003+ Dodge Ram 2500/3500 Heavy Duty Replacement Steering, we have been hoping for a similar solution for Dodge 2nd gen owners. Until now, the only real option was to piece together a 99 HD setup using part store part numbers. These pieced together systems offered a decent temporary replacement, but still wore similarly to the factory steering. Another issue on the 1994-1999 trucks is a lack of compatibility with most aftermarket steering stabilizers.

Fortunately, Synergy is about to change this with their soon to be available 1994-2002 Dodge Ram 2500/3500 4x4 Heavy Duty Steering. It is constructed of 1.5" 4130 chromoly that gets heat treated after the bend. There will be two part numbers - one for 1994-1999 trucks and one for 2000-2002 trucks. The 1994-1999 version includes a bracket that allows you to mount a steering stabilizer in the same location as 2003+ trucks. This bracket can either be welded or bolted on. Check out the pictures:

In the picture above you can see the bend Synergy has provided in the tie rod to clear the pitman arm at full bump. This steering setup did not rub the Mag Hytec diff cover on the test truck.

This steering setup uses Synergy heavy duty tie rod ends, each of which can be replaced as they wear, helping to save costs on future steering maintenance.

The axle side stabilizer bracket above. With this steering setup, 2008.5+ stabilizers can be used, such as the Carli stainless low mount shown above.

Synergy utilizes a fabricated bracket for mounting the stabilizer on the tie rod side, This bracket allows the stabilizer to sit in the optimal position.

This steering setup bolts right to the factory pitman arm and axle with no drilling or modification required.

We are very excited about this upcoming release. More information coming soon!

Thursday, January 28, 2016

Tech tips from the CJC shop Volume #1

Welcome to our new feature! I'm going to try to post frequent short tech articles on questions that we get asked by customers about product installation, troubleshooting common issues, and general maintenance items.

 This issue I would like to go over a part that seems to give people a lot of trouble, the track bar. This seemingly harmless yard long piece of steel is the source of many death wobble and loose steering problems, not to mention those mystery clunks in the night. There are two root causes to most track bar problems (other than joints that are just flat worn out) so let's go over them.

1. Jam nut on the track bar loose. Sometimes getting the jam nut on your track bar tight can seem like an impossible proposition. Don't let this little sucker get the best of you! This is one nut that you can use a big cheater bar on, because the  minimum torque spec is 150ft-lbs. You can go much higher, so don't be afraid to really employ some leverage on this one. Some track bars use a high clearance nut that barely has any flats ground into it, for those I recommend a pipe wrench and a cheater pipe. You can clamp the free end of your track bar into a vice, or a press, or you can pin it into your receiver hitch. You can also pin it into the track bar mount and let the bar stick out through the wheel well so you can let it rest on your knee while you tighten the heim or Johnny Joint end. Don't forget the thread locker.

2. Track bar bushings loose or prematurely wearing out. The first questions I always ask someone that tells me that their new track bar's bushing end has excessive play is: "What size track bar bolts do you have, and what did you torque them to?" If you can't answer those two questions, you probably didn't use torque wrench, and the bolt probably isn't tight enough. If you drive your truck with a loose track bar bolt, you can destroy your brand new track bar bushing in just a few miles. Please invest in a torque wrench! The second common failure is not greasing the crush sleeve before installing it into the bushing. The grease fitting on the track bar does not do a very good job of lubing the crush sleeve, you are much better off taking the sleeve out once in a while and greasing it by hand. If you do choose to leave it in and grease via the zerk, loosen the bolt, grease, then retighten using your torque wrench! If you want to eliminate the bushing fiasco altogether, we offer a Carli track bar that does not utilize the two piece bushing at the frame like most other adjustable track bars for Dodge trucks.

Thanks for tuning in, there are plenty more to come. If you have something you would like me to address in an upcoming article, post in the comments section.


Tuesday, January 26, 2016

January 2016 Builds

January has featured some incredible builds so far! Here are some of the highlights:

The owner of this 2014 Super Duty drove 6 hours to have us equip it with a Carli Suspension Pintop 4.5" Lift system, 17" Method Machined NV wheels, and 37" Toyo MT tires.

This brand new 2016 Ram 2500 Mega Cab features a Carli 2014+ 2500 Pintop 2.5 system, 18" Method Double Standards, and 37x13.5x18 Toyo MT tires.

Here is another shot of the above truck showing the clearance that these wheels offer. With 5.75" backspacing wheels, the furthest point on the lugs of the 13.5" wide Toyos sticks out just under 1".

This 5.9 Mega Cab features Glassworks Unlimited fiberglass installed by True Bliss Customs, a Carli Suspension system, Method Race Wheels Mesh 17's, and 37" Toyo MT's.

This 2015 Ram 2500 features a Carli Back Country 2.0 system, 17" Method NV's, and 37" Toyo Open Country R/T's.

Here is a shot of our friend in Brazil's 2012 featuring a Carli Unchained 3.5 system, Thuren Fabrication Alien Arms, Patton Fabrication traction bars, Trail Ready beadlock wheels, and 37" Toyo MT's.

This 2015 F250 features a Carli Pintop leveling system, 17" Method Standards, and 35" Toyo MT's.

Here are some pictures of a 2016 2500 with a Carli Pintop system. This truck is running factory 20's with 37x12.5x20 Toyo Open Country R/T tires.

Here is a current shot of our shop 2010 featuring a Carli Unchained 3" Long Arm System, PM Truck Wheels, Mercenary Off Road bumpers, Baja Designs lighting, and 37" Toyo Open Country R/T tires.

For more information on Carli Suspension products, visit