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Carli - RAM 2500/3500 6" UNCHAINED 3.5 System, BASE, Diesel 03-09

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CARLI Suspension - Dodge 6" UNCHAINED 3.5 System, Diesel, 4WD, 2003-2009 BASE

SKU: CS-DUC35-6-03

The Unchained is a purpose built kit. 3.5" Front Kings and 4-Tube Bypass rear 3.0" shocks are paired with optioned Torsion Sway Bar, High Clearance Control Arms and Full Leaf in the rear for unsurpassed off-road capability from a bolt-on suspension system. A roll cage should be considered at this level of suspension.

Shock Diameter - 3.5"
Front Lift - 6"
Rear Lift - 4"
Tire Size - Up To 37"
Front Travel - 12.5"
Rear Travel - 13"

Base Kit Includes:

CS-DMRC6-03-D - Multi-Rate Coils
CS-DPRB-03 - Track Bar
CS-DPRBDROP-6 - Track Bar Drop Bracket
CS-DRAPKG-03 - 6" Radius Arms
CS-DRA6-DROP-03 - Radius Arm Drop Brackets
CS-DCM6-03-L - Radius Arm System with Long Crossmember
CS-DUC35SPKG-6-03-D - Unchained 3.5" Shock Package, Stainless Shafts, Limit Straps, Short Reservoir Mounts
CS-DFST525 - Fabricated Shock Towers
CS-DRBD-6 - Rear Bump Drops
CS-DFBD-6 - Front Bump Stop Drops
CS-D6BBL-03 - Brake Lines
CS-HOLESAWKIT-4.5 - 4.5" Hole Saw And Arbor
CS-DRSMKIT-03 - Rear Shock Mounts
CS-D30GUSSET - Rear Shock Gusset Kit

A “Base Kit” SKU must be accompanied by the SKU of a Sway Bar and Leaf Spring option to form a complete system.

2003-07 Rams MUST convert to factory “T-Style” steering

Kit Options:

Sway Bar Option

 

6in Torsion Sway Bar +$
SKU: CS-DTSB6-03
     - Easily the Best "Bang for the Buck" Upgrade for ride quality
     - Allows front suspension to move freely without giving up Control

       

Rear Leaf Options

 

6in Diesel Full Spring Pack +$
SKU: CS-DFSP-6-10-D
     - Softens initial spring rate at ride height
     - Minimizes Axle Wrap/Wheel Hop
     - Reduces Payload 15% From Stock 2500
     - Capable of 15" of Suspension Travel

       

Add Long Travel Air Bags

Long Travel Air Bags 03-08
SKU: CS-DLTB-03-4.0 
- Supports up to 12 inches of travel
- Compatible with 1"-2" Rear Lift, 4" requires CS-AIRBAGSPCR
- Restore Factory Payload to Full Progressive Spring Equipped Rams
- Adjustable Rear Loaded height, 2,000lbs (each) Capacity at 100psi
- Fitment: 2003-11 Ram 2500/3500 4x4 Diesel, 4.0" Axle Tube
- Non Traction Control Equipped, Single rear brake line ONLY

Add Air Bag Spacer

Air Bag Spacer
SKU: CS-AIRBAGSPCR
- Spacer adapts Carli Long Travel Airbag Systems to 4"-lift Spring options
MUST be used with Long-Travel Airbags on Carli 6" Suspensions
- Includes all mounting hardware
- Installs between UPPER bag bracket and Airbag.

Airbag Spacer

Add Pitman Arm

Drop Pitman Arm 03-08
SKU: FTS-93001
- Fabtech Forged Pitman Arm For Use with 6" Front Suspension Lift
- Must be combined with a track bar bracket of equal Drop
- Fitment: 2003-2008 Ram 2500/3500 4x4 Diesel with original Steering Gear

 

Drop Pitman Arm 09-13
SKU: FTS-93012
- Fabtech Forged Pitman Arm For Use with 6" Front Suspension Lift
- Must be combined with a track bar bracket of equal Drop
- Fitment: 2009-2013 Ram 2500 4x4 Diesel
- Fitment: 2009-2012 Ram 3500 4x4 Diesel
- Fitment: 2003-2008 Ram 2500 4x4 Diesel with Larger 6-Bolt Mopar Box

      

Add Carrier Bearing Drop

Carrier bearing Drop +$
SKU: CS-CARRIERDROP-D
     - Drop Bracket For 2-Piece Driveshaft

     

Add Steering Stabilizer

T-Style Stainless Low Mount Stabilizer +$
SKU: CS-DLMSS-T
     - Direct Bolt-In Replacement
     - Corrects Right Tire Pull
     - Can be Combined with Diff Guard and Bracket to correct Left-Tire Pull

     

T-Style Stainless High Mount Stabilizer +$
SKU: CS-DHMSS-03-T
- Direct bolt-in replacement for "T-Style" steering
- Corrects right tire pull, adjustable
- Fits Leveled & Lifted trucks, ONLY
- Does NOT Fit with Factory Power Wagon Sway Bar.

T-Style Stainless Opposing Stabilizers +$
SKU: CS-DSSOSK-T
- True opposing steering stabilizer setup, High & Low Mount
- Nitrogen charged, stainless, adjustable shocks
- Adjusts for any radial pull
- For leveled and lifted heights only
Fits "T-Style" Steering
- Differential Guard and Bracket included

Add Hydraulic Bump Stops

Hydro pneumatic Front Bump Stops 6" Lift +$
SKU: CS-DHYDRO-F-6
- Engages the last 2.5" of Travel Stroke
- Carli Specific, Inverted 2.0" King Bump Stops
- Compatible with 6" Front Lift
- Creates a position sensitive compression zone
- Requires Welding
- Fitment: 2003-12 Ram 2500/3500 4x4

Add Axle Truss

Front Axle Truss +$
SKU: CS-AAMTRUSS
MASSIVE axle support ensures the axle stays true no matter the beating
- 1/4" Cold Rolled Steel Construction with full-length internal X-Bracing
- Includes Upper C Gussets & Lower C Doubler Plates
WELD-ON Fabrication Part

Fabricated Axle Truss

 


Description:

Where the Dominator 3.0” is more balanced, the tuning in the UnChained System is enough to put the build quality of the rest of the truck to the test. At this level of suspension, customers should install a cage as the off-road capability far exceeds the capability of the truck itself. The Front Boasts massive, long-travel 3.5” King Shocks with an off-road oriented tune; the rear, 3.0” 4-Tube King Bypass Shocks. The 4-tube bypass will have far more bottom-out resistance than their smooth-body counterparts and their capability is user tunable to achieve exactly the rear ride desired by the purchaser (More on this in “The Details”).

What does all this mean? Uncompromised off-road ability with an amazing on-road ride resulting in a truck that’s a blast to drive in all environments.

The Details:

The Carli 6” Systems are an entirely different animal than the 3” offerings. There is no entry level; every system is equipped with a custom tuned shock package and Radius Arm Conversion. The longer, flatter links cycle more linear travel and offer a superior ride quality over extending a short arm to work with a 6” front lift. Complete with a Driver’s side axle shock, Carli radius arms allow the axle to roll as to not bind during articulation; think of it as the strength of a radius arm and articulation capability of a 4-Link. Further, the drop brackets that affix the radius arms to the frame bolt on with no modification to the existing, factory control arm brackets (ensuring the truck can be returned to stock). The arms themselves boast “X” bracing internal to their gusseted, clam-shell structure and are constructed with 3” Currie Johnny Joints and an internally gusseted, 1-piece Crossmember (Dominator and UnChained only) making them both serviceable and nearly indestructible.

The UnChained Suspension system is the only kit running a shock tune specifically for off-road. At this level of suspension, customers should install a cage as the off-road capability far exceeds the capability of the truck itself. This system was tuned with 37” x 13.5” Toyo M/T at 40F/35R.

The UnChained system features front Carli Signature tuned, King 3.5” remote reservoir shocks so large, we needed bore the factory spring buckets for them to cycle properly. As the old adage goes, there’s no replacement for displacement. In an effort to provide customers with the best product, we do not sell off-the-shelf King shocks. We spent countless hours dialing in an off-road oriented tune to ensure we maximized the performance of these monster-shocks while maintaining good road manners. To ensure the rear performance is on par with the front, Carli spec’d KING 3.0” 4-tube Bypass Shocks round off the rear.

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.

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 is far less likely to 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. 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.

Your truck will sit 6” higher in the front with 60% more suspension travel than the factory platform thanks to the taller, lighter rate coil springs. The rear is lifted 4” via Carli’s Full Progressive Leaf Pack. The Full Progressive Leaf Pack replaces the entire factory leaf spring assembly increasing travel and drastically increasing comfort throughout the entire usable travel stroke at the cost of a 15% payload reduction from a standard 2500. This payload reduction can be supplemented back to factory capacity with the addition of the Long Travel Airbags (with optional spacer for 6” systems) for the best of both worlds; ride quality and payload capacity/load control. The Full Progressive Leaf Pack requires no block to achieve the 4” rear lift height.

When pairing added travel with the taller ride height, the position of the factory, front sway bar will need to be altered as well. For this, we include a Replacement Torsion Sway Bar. Carli’s Torsion sway bar removes the entire factory sway bar assembly replacing it with a torsion bar supported by fabricated drop brackets and delrin bushings. Fabricated sway bar arms and dual 5/8” FK heim end links round off the package. This is the single best bang for the buck, ride-quality upgrade offered by Carli Suspension (in close competition with the full progressive leaf spring upgrade).

When lifting a straight axle truck, all linkage, brake lines and bump stops need to be addressed. We include extended stainless brake lines, an adjustable track bar + track bar drop bracket, bump stop drop brackets, drop pitman arm, and recommend the purchase of a carrier bearing drop bracket in the rear for those running a 2-piece driveline.

Wheel and Tire:

This system will fit up to a 37” tire on wheels no more than 9” wide with 4.5” of backspacing. 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:

System Notes:

Wheels - Carli Recommends a 17"-18" Wheel, no more than 9" wide with 4.5" of Backspacing on 6" Systems

Tires - 37", E-Rated Tire Fitment is Recommended. Recommended unloaded Tire Pressure 45F/40R

Recommended Configuration - Carli 6" Suspension 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.

Endlinks - 2010-2013 vehicles have 2 possible sizes of Sway Bar End Links. Place a socket on the nut that compresses the rubber End Link bushings; fitment of an 18mm socket will indicate the need for the 12mm Extended End Link.

Torsion Sway Bar - Selection of the Torsion Sway Bar Replacement will not Require size selection as the entire sway bar assembly is replaced.

Front Drive Shaft - Front drive shaft MUST be lengthened 2"

Rear Drive Shaft - Rear Driveshaft must be checked for 1 piece or 2 piece units. It is recommended that 2 piece Driveshafts order a carrier bearing drop, PN# CS-CARRIERDROP-D

Pitman Arm - A drop pitman arm is REQUIRED for 6" suspension kits. Pitman Arm Selection: [2003-2008: CS-PITMAN6-03]; [2009-2013: CS-PITMAN6-09]

Steering Linkage - Carli 6" suspension kits MUST run T-style steering linkage. Y-style linkage does not have enough angle of articulation to support the additional lift height and travel.

 

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