Carli Pathfinder suspension

@TheBlackPearl nice truck.

Finally got my Pathfinder setup installed end of last week and figured I’d share. I went with:


  • Level-height Pathfinder
  • Torsion sway bar
  • Full progressive rear leafs
  • Carli shackles
  • 37x12.5R17 Toyo RT Pros on Battle Born Sierra 17x9 0mm offset

Honestly, I’m blown away with how this setup turned out. I tried to keep my expectations in check — you read all the internet chatter like “yeah Carli is great, but it’s still a truck, it’ll always ride like a truck.”


That’s true to a point, but man, this thing rides WAY better than I expected. Small bumps are so much more muted, and those sharp hits that used to make the whole truck twitch are just... gone. The truck stays totally planted and composed. Bigger stuff — potholes, expansion joints, driveways, curbs — are basically non-events now. It’s hard to describe because you still feel you’re driving over something, but the truck doesn’t get upset at all. Just stays predictable and settled.


Only got about 200 miles on it so far and no off-road time yet, but I can already say this setup is worth every penny. Can’t wait to get it in the dirt and really see what it can do.
Congrats!!! Looks so good!
 
@BLACKCHERRY So I had a little accident last week. Originally I thought no damage other than needing to re-mount my passenger front tire due to dirt wedged in the bead, but after washing it I found two small dents on the rear side of the bed and my Carli Torsion Sway Bar cable disconnected at the end link. I knew an alignment was needed because the steering wheel is cocked just slightly to the left. It drives perfectly fine otherwise. Tracks straight (maybe due to the dual opposing steering stabilizers) and no shake or wobble.

My question is, will Carli sell me just the one sway bar end link, or force me to purchase the whole kit with drop brackets that I won't need?

Also, anyone has recommendations for a decent chain set? MT Baja Boss A/T's didn't help. I was going 20 and driving cautiously.
 

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@BLACKCHERRY So I had a little accident last week. Originally I thought no damage other than needing to re-mount my passenger front tire due to dirt wedged in the bead, but after washing it I found two small dents on the rear side of the bed and my Carli Torsion Sway Bar cable disconnected at the end link. I knew an alignment was needed because the steering wheel is cocked just slightly to the left. It drives perfectly fine otherwise. Tracks straight (maybe due to the dual opposing steering stabilizers) and no shake or wobble.

My question is, will Carli sell me just the one sway bar end link, or force me to purchase the whole kit with drop brackets that I won't need?

Also, anyone has recommendations for a decent chain set? MT Baja Boss A/T's didn't help. I was going 20 and driving cautiously.
Wow, i can't believe you came out of that with only a slightly dented bed and broken sway bar link!

Have you tried inspecting the threads on the link and reassembling? Maybe it unthreaded and didn't pull apart? If you clean it up and shoot some pictures of inside, i can confirm if the bronze race is still there to be able to put it back together.

If your wheel is off center, you either bent your track bar or bent your steering; these trucks aren't like an IFS where you slip a cam bolt; they don't come out of alignment unless something bent.

Shoot a couple pictures of your track bar too; specifically the bend by the axle joint. I'd like to have a look to see if it bent when you laid the truck over as that would've taken all the force.

DM me all this - I can help you out with whatever parts are needed to get you back on the road!
 
@BLACKCHERRY So I had a little accident last week. Originally I thought no damage other than needing to re-mount my passenger front tire due to dirt wedged in the bead, but after washing it I found two small dents on the rear side of the bed and my Carli Torsion Sway Bar cable disconnected at the end link. I knew an alignment was needed because the steering wheel is cocked just slightly to the left. It drives perfectly fine otherwise. Tracks straight (maybe due to the dual opposing steering stabilizers) and no shake or wobble.

My question is, will Carli sell me just the one sway bar end link, or force me to purchase the whole kit with drop brackets that I won't need?

Also, anyone has recommendations for a decent chain set? MT Baja Boss A/T's didn't help. I was going 20 and driving cautiously.
Glad you are safe. I have these chains and they saved my ass and truck during last years hunting season.
 
Wow, i can't believe you came out of that with only a slightly dented bed and broken sway bar link!

Have you tried inspecting the threads on the link and reassembling? Maybe it unthreaded and didn't pull apart? If you clean it up and shoot some pictures of inside, i can confirm if the bronze race is still there to be able to put it back together.

If your wheel is off center, you either bent your track bar or bent your steering; these trucks aren't like an IFS where you slip a cam bolt; they don't come out of alignment unless something bent.

Shoot a couple pictures of your track bar too; specifically the bend by the axle joint. I'd like to have a look to see if it bent when you laid the truck over as that would've taken all the force.

DM me all this - I can help you out with whatever parts are needed to get you back on the road!
DM-ing you now
 
Glad you are safe. I have these chains and they saved my ass and truck during last years hunting season.
These look solid! What tires are you running? Do they hit your wheel wells or fenders? I've got Arena 20" with MT Baja Boss 37x12.50's at 0 offset.
 
Got the pintop done today. So far, Driving around town… I’m impressed. Will test on some 2-track soon.

View attachment 236459
I know this is a Pathfinder thread, but as someone who drives hard, this is my favorite kit for the $$. Keep us posted!
 
Carli level pathfinder all the front end goods minus the lower stabilizer.
Stock leafs with tremor block (for now)
Full travel bags
Bd linkable on bmc brackets
Foundation wheels with omf ring
At3s 37x12.50x18
 

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Wow, i can't believe you came out of that with only a slightly dented bed and broken sway bar link!

Have you tried inspecting the threads on the link and reassembling? Maybe it unthreaded and didn't pull apart? If you clean it up and shoot some pictures of inside, i can confirm if the bronze race is still there to be able to put it back together.

If your wheel is off center, you either bent your track bar or bent your steering; these trucks aren't like an IFS where you slip a cam bolt; they don't come out of alignment unless something bent.

Shoot a couple pictures of your track bar too; specifically the bend by the axle joint. I'd like to have a look to see if it bent when you laid the truck over as that would've taken all the force.

DM me all this - I can help you out with whatever parts are needed to get you back on the road!
Awesome customer service!
 
Dude, TOTAL Class Act! Thank you, Dan!!! We were able to repair the end-link and I am back to good.
That is awesome!

I had a situation where my end links came undone and had to wait to order parts to repair, so I went ahead and purchased a full rebuild kit for mine so I have it on hand just in case
 
Hopefully I'm not too late to the party to ask some questions.

I am trying to decide on what kit to get. I was looking at the Pathfinder kit plus torsion sway bar, upper and lower stabilizers. and.... I WAS also considering the progressive leaf springs

A month ago I unfortunately purchased and had installed an Air Lift 7500XL air bags and have now been told that they are not compatible with the Carli Progressive leaf springs.

So if I have to keep my F250 Tremor leaf springs, as I don't want to lose the $ I paid for the air bags, do I need to go with the Commuter kit instead?

I like the idea of the 2.5 shocks, even though I don't off-road but we have very rough and bumpy country roads here and I also tow about 25% of the time (up to 11,000 Lbs). Was hoping to get the Pathfinder kit but if they aren't meant to go with stock Tremor leaf springs what should I do?

Some people are saying just to buy Fox 2.5 shocks separately. Some said Bilstein 5100s. Some said Pathfinder is fine with stock leafs but I read on these forums that they are not tuned for stock springs.

Would love some help in sorting out my best case set up given that I've already committed to the Air Lift air bags. Thank you in advance!!!!
 
Hopefully I'm not too late to the party to ask some questions.

I am trying to decide on what kit to get. I was looking at the Pathfinder kit plus torsion sway bar, upper and lower stabilizers. and.... I WAS also considering the progressive leaf springs

A month ago I unfortunately purchased and had installed an Air Lift 7500XL air bags and have now been told that they are not compatible with the Carli Progressive leaf springs.

So if I have to keep my F250 Tremor leaf springs, as I don't want to lose the $ I paid for the air bags, do I need to go with the Commuter kit instead?

I like the idea of the 2.5 shocks, even though I don't off-road but we have very rough and bumpy country roads here and I also tow about 25% of the time (up to 11,000 Lbs). Was hoping to get the Pathfinder kit but if they aren't meant to go with stock Tremor leaf springs what should I do?

Some people are saying just to buy Fox 2.5 shocks separately. Some said Bilstein 5100s. Some said Pathfinder is fine with stock leafs but I read on these forums that they are not tuned for stock springs.

Would love some help in sorting out my best case set up given that I've already committed to the Air Lift air bags. Thank you in advance!!!!
Run the pathfinder with your factory leafs and Carli shackles. Even just the shackles made a massive difference.
 
Run the pathfinder with your factory leafs and Carli shackles. Even just the shackles made a massive difference.
Thank you! I am very tempted to go this route. However I did read, I think it was from Blackcherry (I think he works with or for Carli?) said someone in these forums that there can be a "floating" issue in the rear if you use the softer Pathfinders with stock Tremor (which is F350) leaf springs. Is this a concern? I think there was more that he said as well, something to that made me worry Pathfinders wouldn't be the best option for me and to consider the Commuters instead.
 
Thank you! I am very tempted to go this route. However I did read, I think it was from Blackcherry (I think he works with or for Carli?) said someone in these forums that there can be a "floating" issue in the rear if you use the softer Pathfinders with stock Tremor (which is F350) leaf springs. Is this a concern? I think there was more that he said as well, something to that made me worry Pathfinders wouldn't be the best option for me and to consider the Commuters instead.
Avoid the commuters IMHO.

Remember, ride it subjective. You can always add the leafs later if you don't like the ride (I wouldn't add leafs based on my experience for any reason). You also have the option for the Pintops.

Also, you really should add the Radius arms. Your alignment will thank you later.
 
Thank you! I am very tempted to go this route. However I did read, I think it was from Blackcherry (I think he works with or for Carli?) said someone in these forums that there can be a "floating" issue in the rear if you use the softer Pathfinders with stock Tremor (which is F350) leaf springs. Is this a concern? I think there was more that he said as well, something to that made me worry Pathfinders wouldn't be the best option for me and to consider the Commuters instead.

Floating or like a light ass end during spirited driving is normal for suspension designed for heavy load. It’s not the ideal feel obviously but it’s manageable. Carli’s kits are designed as systems so for like peak performance you’d want the full kit. But a compromise of the factory leafs with their shocks and shackles I feel nets you ~ 70% of the system. In my opinion it’s worth it. Plus you can always do the springs later if you choose to. You’ll already have the shocks and shackles and air to support them.
 
Avoid the commuters IMHO.

Remember, ride it subjective. You can always add the leafs later if you don't like the ride (I wouldn't add leafs based on my experience for any reason). You also have the option for the Pintops.

Also, you really should add the Radius arms. Your alignment will thank you later.

+1 on the radius arms. My kit with just the drop brackets aligned fine but as I beat the shit out of the truck and get it realigned it’s never been as good. Def grabbing the arms, maybe on Black Friday if Carli offers any specials.
 
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