Third Gen Cummins Overland Prerunner | Carli Suspension Unchained System Build

Dan Tourino of Carli Suspension started his third gen Cummins build with basic plans, but they slowly snowballed into a full blown avalanche. This truck is now capable of doing quite literally anything, and looking good while doing it!
What's on This truck:
* Carli Long Arm Unchained
www.cjcoffroad...
* Torsion Sway Bar
* Custom Deaver Leaf Springs
* Carli Ball Joints
* Carli Billet Motor Mounts with Kalil-fab custom frame engine cradles/coil bucket supports
* Axle Truss
* Hydro Bumps
* APEX Steering
* PSC Big Bore Steering Gear
* PSC Hydro Assist
* 14+ R/R Ram PS Pump
* Radial Dynamics PS Reservoir
* Mercenary Offroad front and rear Bumpers
* Warn VR12S Winch
* Factor 55 Fairlead and Ultra-hook
* Baja Designs 30” ONx6, Squadrons and S2
* ADV Fiberglass
* Wheeler Industries inner and Outer fender liners
* Retro-Shop Headlights
* AMP Steps
* JL Audio C3-650 Components, HD900/5 Amps, 10TW3 Sub in JL Stealth Box
* Isspro Performax EGT, Boost, Fuel Pressure, Trans Temp
* Randy’s Transmission Stage 2 Trans
* PPEI Custom tuning
* Fass Titanium Signature Series 165 Lift Pimp
* Industrial injection VIPER 63/80
* Industrial injection 60HP Injectors
* Industrial injection Stage 1 CP3
* ARP Studs
* Fleece Coolant Bypass
* S&B Intake
* S&B Intake Elbow/Horn
* S&B 53 Gallon Mid-Ship Tank
* Mishimoto Transmission Cooler with FSD Line kit
* SPOD 4x4 6-switch panel with custom stainless overhead console switch mount
* Kenwood TM-281A Race Radio
* (2) Odyssey 65-PC1750T relocated to the bed
* GFC with kalil-fab bed-cage
* Brixton Fab Spare Tire Holder
* Patton Fab Bed Supports
* Icky Concepts Bulkhead panel
* Pro-Eagle In-bed Jack
* KMC Grenade Beadlocks, 17x9, 0 offset (at time of video)
* 40” x 13.5” Toyo MT
* Yukon 4.56 Gears
* Yukon Grizzley Rear Locker
* Front Power Wagon E-Locker
* Dynatrac Freespin Kit with Dyna-Locks
* Rebuilt Factory Drivelines and Transfer Case
#carlisuspension #cjcoffroad #thirdgencummins

[@unknown_truckers]

Yall could make a whole series of all of yalls builds, running them hard off road. And we would watch all of them

[@ZJ_Rubicon]

My brain almost can't comprehend a fullsize truck doing that with basically bolt on suspension. So freaking cool!

[@purebloodedpatriot9352]

I can

[@JasonWh]

I can speak to it being true as I have their pintop system with radius arms on my 22 power wagon and I best the snot out of it in the desert of Adelanto CA and parks in Austin TX both! Never had an ounce of trouble and I should have broken a few parts given my antics.

[@3rd_gen_j]

He beat all of us to building the dream!

[@JamesPatterson-w9l]

Carli suspension upgrades really helped improve ride quality on my 4th gen. Only complaint is how fast these components rust in the Pacific Northwest Region

[@brandonjjarvis]

Which parts have rusted on you? I am in the same area and am upgrading slowly.

[@armandotoledo275]

The king shocks finish looks crappy pretty quick. Get the protective wrap

[@LuciferLoveTV]

This is my dream setup! beautiful truck!

[@Sickksidex3]

THE TRUE TRX.

[@mikesevilla8692]

I bought a third gen based off of these carli vids. I have the ball joints. The hardest part is securing the funds to get the rest of the suspension componenets

[@9aqua_man282]

Making a call to my local credit union 😂. Wife’s on board. Wish me luck boys.

[@icmacd]

As a 3rd gen owner this makes me soooooooooo happy!!! 40s and GFC at speed

[@JasonWh]

I’ve done almost all these things other than a few of the high speed off angle things, slow and fast scenes, in my ‘22 Power Wagon on 37’s running the full Carli Pintop system with Carli radius arms and dual steering stabilizers. The capability is out of this world. I’m also running the Same GFC camper shell with tent. The suspension upgrades, although almost $10k were so worth the money, I’d do it all over again! The installation was so perfectly planned we never once needed even so much as a rubber mallet to move things into place. Carli I’d be happy to drop by and let you record a video hooning my build. Heck I have your name on the side of my truck bed in vinyl!!

[@desertoutlaw3317]

thats awesome

[@desertoutlaw3317]

id love a kit for my third gen

[@desertoutlaw3317]

makes me want to make my diesel a capable offroader rather than buying an old chevy to turn into a desert truck which was my original plan

[@Captain-Awesome]

@@desertoutlaw3317Look for the 2006 and 2007 5.9 Cummins. It has the newer design interior and exterior without any of the emissions. Remember when looking that they only put the 5.9 Cummins in first part of 2007. The second half is the 6.7 Cummins which is a great engine but does have the fist of the emissions which will be the item that breaks and cost a lot to fix.

[@desertoutlaw3317]

@@Captain-Awesome haha i own a 2007 5.9 cummins

[@blackpearl7144]

Wow crazy. I just ordered my 2.5 backcountry for my 17 F250. You guys are awesome,I watch all your videos.

[@CJCOffRoad]

Right on! That system might not do this kind of stuff, but it's such a huge improvement from stock

[@blackpearl7144]

@@CJCOffRoad lol yes. I’ll be pulling a 5th wheel and some light off road/hunting trips to Colorado. I would however run the 4.5 inch if it would work on my 5th wheel, but my shop wasn’t for sure if it would work. I plan on running 37/13.50/17 Toyo m/t with the method 305 nv with a 0 offset.

[@Lochlann13]

This is such a sick build. It does make me wonder though, with all that budget, why didn't he swap the rear leaf springs out for coilovers? Or was the goal to use only Carli parts?

[@TW-pq3hn]

By far the best video yet!!! Make me wish I had a 3rd gen instead of my Superduty! Great job as always!

[@Daniel-1-1-1]

My fully optioned dominator kit truck has still not seen dirt 😢 Shoutout to the best best Off-road shop CJC!!! Order up boys and girls…Cole and Cody offer the best customer service…trust me…I know for a fact.

[@1qforan]

awesome video. unrelated but I checked your site for any seat covers. You guys must be getting these trucks dirty in the desert!! HAHA. Any recommendations on great fitting and protective seat cover manufacturers.

[@es.photography]

Yup , 💯🐓💪

[@samly1762]

Great Build. What are the HP/Torque numbers ??

[@CJCOffRoad]

It's never been dyno'd but depending on tuning this setup should be somewhere in the 600-650hp range. That said, Dan runs it on the lower side of tuning, since you just end up breaking things when shock loading the whole drivetrain through whoops under power.

[@seabass3104]

That dodge rattles and squeaks like a mofo guaranteed.

[@bakernathan98]

I love the early gen 3s my favorite truck before the headlight revamp I inherited one from my grandmother its gas but I love it rusted rocker panels and rear fenderwells and all . Can anyone tell me where I can get similar build parts for my Ram 1500 4x4 5.7 Larmie. ? I want this same thing just in a 1500.

[@6pR9MK]

Could you or Dan T give any more info about the 14+ power steering pump and custom reservoir setup that is talked about at the 6 min mark in the video? I'm running the 6.7 power steering pump and reservoir on my '07 5.9 with 37's, but always looking for any improvement possible. Thanks

[@ExhumedToConsume]

"Honey, the cutlery is all over the place again"

[@MdubFrederson]

Good old "3rd gen"... so basically rebuild the entire truck. Nothing will be as good as the pre 98.5 trucks

[@GoldenTroutBFS]

Those Centramtics are pure gold for tire balance monkey insurance.

[@esobeegarage]

Biased cuz I have one but love that it's an early 3rd gen too ;)

[@fredeschen3783]

My 3rd gen goes around a thousand miles on a full tank. Probably 1500 with that big tank.

[@Bosscrits]

I have that exact model of truck. Please bundle me up the package and send it ❤❤❤… and the bill

[@pretx9569]

Absolutely insane! 👍🏼

[@hibiki54]

Seeing the shop Power Wagon always tickles my pickle. As for Dan's truck, I'm actually surprised that he didn't swap out the 24v for a 12v.

[@CJCOffRoad]

No reason to! The 24v makes plenty of power, plus you get the added control of electronic injection and variable timing based on tuning. The 5.9 Common rails are a fantastic platform and work better for this purpose than the mechanical 12v cummins.

[@Bjartr-b6o]

Third gen > everything. og headlights too not 06 lol

[@delcoboyz8253]

Love this build! Kudos to Dan Tourino, Carli, and CJC !!

[@jdirt1982]

This truck needs to be on this vs that. For fucks sake....

[@navseal345]

🤯 Id just like a ride, lol.

[@hill160881]

Love it but I have to ask why no skid plates? Weight? I have a f450 and won’t get it in the rocks until it has skid plates.

[@CJCOffRoad]

Since Dan primarily uses this truck for high speed desert stuff (since that's what we have access to down here) and not low speed rocks like the Rubicon trail, it just didn't make sense to add skid plates when they wouldn't be utilized.

[@brandonjjarvis]

Trying to learn about this stuff: Is it me or are the rear shocks slow on rebound compared to the front? You can see the rear doesn't plant very well in allot of the shots and the jumping slow mo just watch the rear slowly get to full extension. Badass truck!! Trying to find a paint peeling farm beater single cab for this thing:)

[@CJCOffRoad]

These are rear bypass shocks so you can actually adjust rebound through different areas of the piston stroke. Dan has been messing with the rear a little bit to find the best balance with the camper on the back so you're spot on that the rebound hangs a little especially in the road gap clip. That said, the beauty of bypass shocks is that you have full control by making tube adjustments on top of the base valve.

[@bigdogbuilds]

Amazing guys! Maybe we will find a barn find in australia to do something silly like this one day 😍😍

[@CJCOffRoad]

We’ll trade you for a 200 series? 😂

[@christiandulaney1638]

I LOVE what you guys do with Rams down in Australia! They are all aesthetically perfect! Gorgeous trucks

[@Thatsoverrated]

Need more action clips without the music!

[@CJCOffRoad]

Sadly it was insanely windy on the desert days, so 99% of the high speed clip audio was just howling wind. Bummer since Dan’s truck sounds so good! We left any usable audio we could.

[@NathanielCruz-n5l]

How much is in this truck ? A need to know question

[@eclifton4070]

I need to bring my 2000 F350 7.3 with the Carli unchained system over sometime for you to take a look at. As you know, it was originally a leaf sprung on a Dana 50. It now has a true F550 Super 60, narrowed with free spin hubs. It also has your long travel airbags and military beadlock wheels. And yes, custom colored shocks too with a Mercenary Offroad bumper. I built it back in 2019. Love your suspension but need to have it tuned at some point. It feels a bit tired.

[@TWestOutdoors]

Would love to see that dash after all that desert riding 😂

[@CJCOffRoad]

Amazingly it's still holding together!

[@EasyStar013]

YES. YES. Everything YES! Dream build for sure. I wish you would have included everything you did to the truck in your parts breakdown. The list seems a little short to me...(kidding!). #dreambuild #takeyourhypercariwilltakethis Thank you for sharing!

[@DanTourino]

• Carli Long Arm Unchained • Torsion Sway Bar • Custom Deaver Leaf Springs • Carli Ball Joints • Carli Billet Motor Mounts with Kalil-fab custom frame engine cradles/coil bucket supports • Axle Truss • Hydro Bumps • APEX Steering • PSC Big Bore Steering Gear • PSC Hydro Assist • 14+ R/R Ram PS Pump • Radial Dynamics PS Reservoir • Mercenary Offroad front and rear Bumpers • Warn VR12S Winch • Factor 55 Fairlead and Ultra-hook • Baja Designs 30” ONx6, Squadrons and S2 • ADV Fiberglass • Wheeler Industries inner and Outer fender liners • Retro-Shop Headlights • AMP Steps • JL Audio C3-650 Components, HD900/5 Amps, 10TW3 Sub in JL Stealth Box • Isspro Performax EGT, Boost, Fuel Pressure, Trans Temp • Randy’s Transmission Stage 2 Trans • PPEI Custom tuning • Fass Titanium Signature Series 165 Lift Pimp • Industrial injection VIPER 63/80 • Industrial injection 60HP Injectors • Industrial injection Stage 1 CP3 • ARP Studs • Fleece Coolant Bypass • S&B Intake • S&B Intake Elbow/Horn • S&B 53 Gallon Mid-Ship Tank • Mishimoto Transmission Cooler with FSD Line kit • SPOD 4x4 6-switch panel with custom stainless overhead console switch mount • Kenwood TM-281A Race Radio • (2) Odyssey 65-PC1750T relocated to the bed • GFC with kalil-fab bed-cage • Brixton Fab Spare Tire Holder • Patton Fab Bed Supports • Icky Concepts Bulkhead panel • Pro-Eagle In-bed Jack • KMC Grenade Beadlocks, 17x9, 0 offset (at time of video) • 40” x 13.5” Toyo MT • Yukon 4.56 Gears • Yukon Grizzley Rear Locker • Front Power Wagon E-Locker • Dynatrac Freespin Kit with Dyna-Locks • Rebuilt Factory Drivelines and Transfer Case

[@brokenwrench404]

@@DanTourinothanks Dan. Killer rig 👍🏼

[@DanTourino]

My pleasure and thank you! @@brokenwrench404

[@scrapyardprospecting3855]

Bout time I found something like this I scored a 03 25004x4 that’s in the rebuild it phase of I ever hit the lotto def gunna build one of these at least now I know why everyone keeps trying to buy my truck

[@2L8CO]

Wow! I thought my 3rd Gen build was cool. Not!...Thanks for the new game plan 💥

[@riellywhite4449]

I’ll get mine there one day

[@johnwayne6775]

The only Cummins truck where the block will crack before the truck breaks, usually the othe way round where the truck falls apart around the running engine

[@davewarrant8673]

Looks great! Any rear air bag options? 90% of the time I'm empty and not pulling a trailer, but when I do it tends to be heavy.

[@Blackneck1994]

3rd gen 4 life 🎉

[@AldenPez]

Wow. Only thing i would change for myself is the platform. I’d do a tundra(not the new one) or a newer ram. Nice to know that my dream is possible!

[@Jdwg1972]

Wow!! Awesome machine

[@timothymroberts2949]

Sweet build...what about the 6inch system? I want to know/see how the radius kit performs. Love the video

[@armandotoledo275]

Just swapped my pintop to a long arm dominator on my 3rd gen. The pintop worked amazing but this long arm kit is life changing. Old kit is for sale.

[@MrBpritch100]

Cant haul a 5th wheel....took me a few to think of a legitimately good thing its not able to do. LoL nicely done rig for the purpose!

[@johnomahony7364]

That truck is incredible..does it all and does it incredibly

[@CJCOffRoad]

It's one seriously potent weapon!

[@Krawl913]

I need to meet up sometime and bring my f250 to your shop. Make sure it’s working as good as it should with your pintop kit. Maybe even do a video of hammering it out at this area.

[@allensandven0]

But did you get rid of the death wobble ?

[@toddpratt1626]

What total $ cost? :)

[@DanTourino]

You could expect to be in the low 100K to build this (including the truck) with all parts at retail + installation.

[@deanweller5789]

sorry been looking around online, do you happen to know if 17" rims will fit on my 2023 ram 3500 single rear wheel truck? i worried they might contact the caliper

[@CJCOffRoad]

It's very tight, but they do fit as long as you use static balancing to place the wheel weights away from the caliper

[@deanweller5789]

@@CJCOffRoad Thanks for the heads up "🙂

[@mitchellmartinez8066]

This is a beautiful truck jeez I need this in my life and I own one already lol beautiful build

[@KamdenTracy]

I have an 07 1500 4x4 and would like to use carli suspension. Can you guide me to how to do so. I see almost all of these are diesels. I don’t recall if the lower ends are the same

[@CJCOffRoad]

Sadly none of these systems will work for a 1500.

[@KamdenTracy]

@@CJCOffRoad thank you. Still plan to use you guys with the 5.9 soon

[@calibomber209]

Would doing this to a hemi be ok? 3rd gen?

[@CJCOffRoad]

Absolutely! Hemis have a lower price of entry too

[@ThomasColey-v6z]

Can this applied to a 2005 power wagon ??

[@CJCOffRoad]

Yep!

[@jdesigns7239]

I would have loved to see the inside of the camper.

[@AnthonySvt_]

I’m not much of a mopar guy but this truck is beautiful!

[@madmaxington]

This is the best thing ever. Every other build sucks and this is the best one.

[@Bmxr1991]

I love the west

[@Bmxr1991]

I love the west

[@GG-bl2vm]

Wow this is an awesome rig and definitely gave me some cool ideas for mine.

[@brokenwrench404]

I’m curious about how cerakote holds up on the shocks. I’m on the central cal coast and with constant sea air and the crossing at pismo everything. Corrodes really quickly.

[@DanTourino]

I'm relatively coastal in Orange County, CA. I've now had these shocks for 2 years and they're in perfect shape (short of the sand blasting the rear, forward facing passenger shock has received). I will never own a non-cerakoted King now - they're awesome!

[@tjakra21]

Literally perfect goddamn

[@jackkrinkov9273]

It’s not about the destination it’s about the journey!

[@gofomoplymouth8332]

The setup is very nice, but can you talk more on what direction average people can buy if they pieced it out. You know if their not a vp of a company lol..

[@DanTourino]

This definitely isn't marketed as the every-man's build. Most all CJC vids are about the every-day builds with Commuter, Backcountry and Pintop. Nice to throw in a statement build every now and then!

[@calevel]

Most capable 3rd gen I’ve ever seen!! 😮

[@blindy9897]

I need this for my 2nd gen so badly

[@johnbradtke1494]

That is seriously impressive!

but does the 3" unchained kit made for the hemi

[@CJCOffRoad]

This kit is intended for a diesel, but the shocks could be tuned for a Hemi as well.

@@CJCOffRoad awesome fantastic news !! but what about the spring rate ??

[@Topsecret32]

Didn't this thing just break a axle for being 2ft in the air?

[@CJCOffRoad]

Nope. Different truck maybe?

[@Topsecret32]

@CJCOffRoad really thought it was this one. He was carrying good speed. But it was a long jump in the video, didn't seem super high

[@armandotoledo275]

No that was a 4th gen unchained_longhorn

[@theclinchdrive]

Gday fellas this 3rd Gen is sick what GVM upgrades can CJC offer for this platform? I’m looking at one now for a diesel mechanic set up here in Australia. Or would I be better off going with a 4th Gen 2500 or 3500? I’m in love with the 5.9 common rail no DPF from factory and they sound better then the 6.7 but I carry a lot of tools around and what to be able to load on some parts for jobs. 🤟🏼🤠🕺

[@CJCOffRoad]

If off road performance is the goal, you'll be MUCH happier with a Ford or Ram. You get way more bang for your buck with suspension, and the end capability is pretty much unmatched per dollar spent!

[@theclinchdrive]

@@CJCOffRoad yeah okay ! On road driving ability being able to carry a load does CJC have a suspension set up to raise the payload capacity?

[@CJCOffRoad]

Since you're in Australia, reach out to Big Dog Builds. They can get you set up with the right suspension, and the proper engineering certification.

[@theclinchdrive]

@@CJCOffRoad okay mate they are on the opposite side of the country from myself. Haha could you tell me what the stock factory GVM is on the 3rd Gen 2500? I can’t find a strait answer on google 🤔

[@__-sf7tv]

When a 2nd gen?

[@CJCOffRoad]

While this exact system isn't available for 2nd gens, we can definitely set you up with something similar.

[@ricardor395]

Is there more info about this truck??

[@CJCOffRoad]

What would you like to know?

[@ricardor395]

@@CJCOffRoad parts!

[@ricardor395]

@@CJCOffRoad front axle locker wiring?

[@stevog44]

Anyone know who makes that rear bumper?

[@CJCOffRoad]

Here's a link to it: www.cjcoffroad.com/products/mercenary-off-road-heavy-duty-3rd-gen-03-09-dodge-ram-2500-3500-a-bomb-stock-replacement-rear-bumper?_pos=14&_sid=1e4e3d623&_ss=r

[@workingsumo]

*Props!*

[@CarveyKeitel]

That’s a real nice write off!

[@DanTourino]

VP, no President haha. I didn't get to write-off shit! Luckily i get a good deal on the Carli parts BUT there's a long list of things that came straight out of my pocket.

[@ETal-f4v]

Any rubbing on the cab from the camper?

[@CJCOffRoad]

Nope! There’s plenty of gap with these.