SKU #: CS-FEXP25-main Carli 4.5" Performance 2.5 Suspension System 00-05 Ford Excursion

Purchase Carli 4.5" Performance 2.5 Suspension System 00-05 Ford Excursion
    • 2000-2005 Ford Excursion Powerstroke 4x4
  • Engine Selection


The Ford Excursion is arguably one of the best suited vehicles for overlanding purposes ever produced.  Heck, even the name "Excursion" implies that it was originally intended for adventure.  ... read more

  • Share

Fast and Free Shipping On Orders Over $100

No Salesmen, Just Enthusiasts 888.993.4373

The Ford Excursion is arguably one of the best suited vehicles for overlanding purposes ever produced.  Heck, even the name "Excursion" implies that it was originally intended for adventure.  And why is this?  With room for plenty of people and/or gear, sitting on a 3/4 ton chassis, and available diesel option, what's not to like about this behemoth of a rig?  For starters, if you are ready to get off road, or at least look like you are, the suspension needs some attention, but fortunately, the suspension gurus at Carli have you covered with a system that will not only lift your Excursion for larger tire fitment and ground clearance, but also provide a very noticeable increase in ride quality and overall suspension performance, introducing the Performance 2.5 Suspension System.

  • Carli Tuned 2.5" Remote Reservoir Shocks with Stainless Shafts
  • Reservoir Mounts
  • Weld-In Rear Shock Mounts
  • Front 4.5" Lift Full Progressive Leaf Spring Pack
  • Rear Excursion 2.25" Lift Full Progressive Leaf Spring Pack
  • Front Extended Sway Bar End Links
  • Track Bar Drop Bracket
  • Drop Pitman Arm
  • Extended Braided Brake Lines
  • Rear Bump Stop Strike Plate / Lower Airbag Bracket
  • Rear Bump Stop Drops
  • Front Bump Stop Drops
  • Superior Ride Quality
  • Very Controlled Off Road
  • Increased Cornering Capability
  • Reducing and/or Eliminating Body Roll
  • Corrosion Resistant Stainless Shock Shafts
  • Tighter Street Feel Driving Characteristics, Increased Suspension Response
  • Steering Geometry is All Within OEM Specifications, No Additional Components are Necessary
  • Shock Diameter 2.5"
  • Front Lift Height 4.5"
  • Rear Lift Height 2.25"
  • Tire Size Up to 35"
  • Front Travel 9"
  • Rear Travel 12"
In a market filled with coilover conversions, Carli stuck to the bones of this proven platform. The attention to detail is top notch and shows one can achieve top-tier performance without scavenging a junk yard looking for (and refurbing) steering and axles. The goal was to build a comprehensive system for the customer looking for a reasonable lift height and massive performance improvements on and off-road to compliment the new stance from a bolt-on system. Too many lifts are sold incomplete leaving a customer to search for compatible parts to complete their suspension build; not here"¦ Buy the system, install and enjoy.

This system starts with custom Carli/Deaver Leaf Spring packs for the front and rear. The lighter rate, Full Progressive Leaf Springs lift the front 4.5" and the rear is lifted 2-1/4" by Carli's block eliminating spring pack. This lift and extended travel calls for some geometry changes up-front. The track bar angle is corrected via a Fabricated Track Bar Drop Bracket and a Pitman Arm is provided to ensure the steering (drag link) and suspension (track bar) cycle the same ratio to eliminate bump steer. Also included are a set of Extended Sway Bar End Links to recenter the factory front sway bar in its extended stroke. To this, extended, stainless brake lines were added to firm up braking feel and ensure there was enough line to handle the added down-stroke of the front and rear axles.

The Excursions are big and top heavy, so the assistance of King Shocks were enlisted when looking to keep the lifted center of gravity composed and comfortable. With the help of King, Carli designed a custom 9" Travel, 2.5" Diameter, Piggyback shock for the front and a 12" Stroke for the rear with a custom hose to route the reservoir out from under the body. The only weld-in part, Carli designed a double-sheer shock mount to replace the rear-upper factory "T-Bar" shock mounts for far more strength. Fabricated Bump Stop Drops are included front and rear to ensure the springs and shocks cycle in perfect unison. The King shocks are then finished off with Carli's proprietary 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 can't 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. The shocks are finished with King oil good to -55 degrees Fahrenheit. 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.

The shock experts at Carli then spent significant time on the valving profile. Starting with a custom piston, they found the perfect compromise between on and off-road performance without leaning too far into one end of the spectrum or the other. On road and on the highway, this is one of the best riding kits they've turned out for ANY platform. Body roll is significantly reduced, sharp corners are rounded, wheel hop and axle wrap are eliminated (thanks to the removal of the factory block) and the tires stay on the ground at all times. Off-road, the SUV feels half its size and completely composed. This is not a system designed around whoop pounding or jumping, but dirt roads and rutted trails can be taken at speed with one hand on the wheel. Light to medium duty offroad escapades become completely controlled and uneventful.
The rear springs are a reduced capacity spring pack (reduces payload/hauling capacity to a "light" 3/4ton). If capacity is a concern, the Full Progressive Leaf Springs can be supplemented back to the factory capacity with the addition of Carli's Excursion specific Long-Travel Airbags.

Carli recommends 17"-18" wheels, no more than 9" wide with 4.5" of backspacing with a 35", E-Rated Tire. 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.


  • ManufacturerCarli Suspension
  • MPNCS-FEXP25-60 | CS-FEXP25-73


Blog Posts

Recommended Products

Recently Viewed

Added To Cart

Carli 4.5

Carli 4.5" Performance 2.5 Suspension System 00-05 Ford Excursion

Quantity: 0