F150 Prerunner Builds: Long-Travel Suspension Guide

Taking a late-model F150 and pushing it into desert-running territory requires more than just bolting on a spacer. Our team in Irving builds true F150 prerunner setups designed to soak up massive hits off-road while surviving the daily commute through the narrow construction lanes on I-635 East. We install kits that give you 12 inches of suspension travel, wide-track stability, and room for 37-inch tires.

What this service involves

Building a prerunner means gutting the factory geometry. We replace the stock upper and lower control arms, swap the tie rods, and install extended axles to widen the track width by three to five inches per side. Unlike basic suspension parts, this setup requires high-performance hardware, typically 2.5 to 3.0-inch diameter coilovers with remote reservoirs to handle extreme heat and rapid cycling.

For drivers looking to maximize rear travel, we also fabricate custom rear setups. While a standard leaf pack upgrade works for mid-travel, going full long-travel often involves bed cages or a complete 4 link suspension conversion to match the front capability. Upgrading to this level drastically changes the overall struts and shocks replacement cost, but it guarantees the truck lands smooth when pushed hard off-road.

Who needs it

• Owners of 2021-2026 F150s who want Raptor-level performance without the factory markup.
• Off-road drivers hitting trails at Northwest OHV Park who need maximum articulation and high-speed damping.
• Drivers planning an off-road wheels and 37-inch tire fitment upgrade who need functional travel without rubbing.
• Anyone tired of a stiff ride on rough highway expansion joints who wants a plush, high-speed capable truck suspension setup.

Our exact process

1. Tear down and inspection: We remove the factory control arms, axles, and truck shocks, checking the frame mounts for stress.
2. Front-end geometry installation: We bolt up the widened lower control arms, extended axles, and heavy-duty tie rods.
3. Coilover tuning: We install the new remote-reservoir units, setting the preload to achieve the correct ride height and maintaining the Texas legal headlamp limit of 54 inches.
4. Rear suspension matching: We upgrade the rear with custom leaf packs, bypass shocks, or a four link suspension system to keep the rear end from bucking.
5. Alignment and testing: We dial in the camber and caster for the widened track width, ensuring it drives straight on the highway.

Brands and materials we use

• Baja Kits: Their front prerunner kits for the 2021-2026 F150 offer incredible strength and 12 inches of travel.
• Dirt King: We install their long-travel systems for extreme builds, featuring boxed control arms and high-angle ball joints.
• RPG Offroad: For a milder approach or fine-tuning, their spring perch collars adjust ride height perfectly.
• ReadyLift: We use their 6-inch kits for trucks equipped with the factory CCD system to maintain BlueCruise compatibility.

Timeline and pricing

A true long-travel build takes time. Expect your truck to be in our shop for three to five days, depending on the complexity of the rear suspension and fiberglass fender fitting. The changing shocks and struts cost on a standard truck is straightforward, but a full prerunner conversion is a major investment requiring expert F150 suspension tuning.

Basic mid-travel kits and high-end shock absorber replacement cost between $1,900 and $2,300. A premium Baja Kits front long-travel setup runs $4,099 to $4,859 in parts alone. For a complete Dirt King system with 12 inches of travel, expect $3,500 to $5,500 for the front end.

Frequently Asked Questions

Will a long-travel kit pass Texas state inspection?

Yes. As of 2025, Texas no longer requires mandatory safety inspections for non-commercial vehicles, though emissions testing is still required in major metro counties like Dallas and Tarrant. You do need to ensure your headlamps sit below the 54-inch legal maximum.

How do remote reservoir shocks handle the Texas summer heat?

When pavement temps exceed 110 degrees, standard shocks and struts overheat, causing the fluid to thin and lose damping force. Remote reservoirs increase the fluid volume and cooling area, preventing shock fade during high-speed off-road runs or long highway drives.

Can I keep my CCD suspension on a 2025 F150?

Yes. We provide professional F150 lift kit installation using specific kits designed for CCD-equipped trucks. This allows you to upgrade your ride height and capability without throwing dash codes or disabling the BlueCruise system.