Carli 6" UnChained 3.5 Radius Arm Suspension System 03-09 Ram 5.9L / 6.7L Cummins

Carli 6" UnChained 3.5 Radius Arm Suspension System 03-09 Ram 5.9L / 6.7L CumminsThe 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 Leafs 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. 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

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 Leafs 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.

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").

CARLI UNCHAINED SUSPENSION COMPONENTS

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.

CARLI TUNED 3.5" KING SHOCKS

The UnChained system features front Carli Signature tuned, King 3.5" remote reservoir shocks so large, you'll need to 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 you with the best product, this kit does not include standard off-the-shelf King shocks. Carli spent countless hours dialing in an off-road oriented tune to ensure the performance was maximized out 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.

All of Carli's King shock offerings are finished 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.

REAR LEAF SPRINGS

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.

FULL PROGRESSIVE LEAF SPRING KIT SPECIFICATIONS:

• 2" rear lift maintains slight rear-high stance with Carli 3" stance
• Softens initial spring rate at ride height
• Minimizes axle wrap / wheel hop
• Reduces payload to light 3/4 ton capacity
• Capable of 15" of suspension travel with factory shackle
• Fits 4" axle tube

TORSION SWAY BAR

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, you'll receive 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).

TORSION SWAY BAR SPECIFICATIONS:

• Easily the best bang for the buck upgrade for ride quality
• Allows front suspension to move freely without giving up control
• For trucks with 0-3" of front lift
• Requires removal of electronic sway bar on Power Wagons
• Torsion Bar may be black or silver zinc; depends on supply chain availability. NOT requestable.

ADJUSTABLE TRACK BAR

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

WHEEL AND TIRE FITMENT

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.

IMPORTANT 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.
• FRONT DRIVESHAFT: Front drive shaft MUST be lengthened 2".
• REAR DRIVESHAFT: 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.

RADIUS ARM INSIGHT

The lower part of the arm has a full-length internal gusset, creating 4 triangles inside the arm. Above and below are full length external gussets. This is key set with a plate that is connected to the main box. This creates 2 more triangles on top and 2 more on the bottom. See images above.

When this was designed, it was laser cut so that the welds will tie every plate together. First the internal X is welded up on a jig and then the box is added with the external gussets.

This system's true engineering feat comes in the form of overcoming articulation bind. The engineering that went into this is where the innovation is truly demonstrated. The engineered radius arms will allow for maximum axle articulation, with one shock at full bump and the other at full droop. No castor change bind.

Sage Carli engineered a solution that offers harmonious axle geometry throughout the entire motion range. Ask anyone who has built radius arms, and they will talk about castor change bind, it's nothing new. The Carli engineering approach is, however, something new in a production bolt-on radius arm system for Dodge Ram HD's.

This project was modeled on a computer using factory chassis parameters to ensure precision before plates even hit a laser table. The answer was +/- 3" of upper arm deflection to accommodate travel and articulation specs that exceed the chassis. This component is finished off in classic Carli style using chromoly tube, a billet stainless steel shaft and hard ball center joints.

OPTIONAL UPGRADES

• Leaf Spring Shackle: improves rear ride, greasable/rebuildable, 1/4" steel, fits factory and Carli springs
• 2003-11 Long Travel Airbags: supports 1"-2" rear lift, up to 12" travel, adjustable to 2,000 lbs per bag
• 2012 Long Travel Airbags: supports 1"-2" rear lift, up to 12" travel, includes extended brake lines for traction control trucks
• Airbag Spacer: adapts long-travel airbags to 4"-6" lifts, includes mounting hardware
• Pitman Arm: drop-style arm for 6" lift, corrects steering geometry, forged steel
• Carrier Bearing Drop: lowers 2-piece driveshaft, prevents vibration/shudder, stackable for 1"-4" lift
• Steering Stabilizer: reduces wobble and radial pull, high/low or opposing setup, nitrogen-charged, adjustable
• Hydraulic Bump Stops - Front: engages last 2.5"-6" of front travel, position-sensitive, weld-on
• Axle Truss: reinforces axle, 1/4" steel with X-bracing and gussets, weld-on