American Expedition Vehicles (AEV) has finally added its special sauce to a Ford. That means the three brands of HD trucks in North America can now all be purchased as turnkey, everyday drivers with extreme off-road capability backed by OEM levels of engineering and quality.
AEV has already built proven vehicle systems for the Ram HD platform, with the Prospector and Prospector XL, and the Chevy/GM HD, with the Bison/AEV Edition. Now, they bring the same mindset, feature set, and engineering experience to the Ford Super Duty, with the FXL program.
Where’d the Name Come From?
“F” stands for “Ford” and “XL” is the Roman numeral for 40. This is a direct reference to the goal of the project: “fitting 40-inch tires with the least amount of lift possible.”
Besides big tires, the goal of the AEV FXL project was to create a Ford Super Duty that offers both extreme off-road capability while “maintaining the ride quality, stability, and confident on-road behavior” of the stock truck. Think massively increased flotation and traction for off-road adventures while still being easy to drive around town and do HD truck things, like haul heavy loads and tow big trailers.
Oh, and of course, it looks stout, stands out from the sea of big trucks on the road, and has that unmistakable AEV signature style.
AEV Super Duty Trucks
Both the Ford F-250 and F-350 Super Duty platforms can be upgraded with AEV’s new FXL complement of upgrades. This can come by way of a turnkey truck sold through AEV-authorized Ford Dealerships, a new truck you purchase and send to AEV for an upfit, or by building the truck yourself or at an upfitter shop with the new AEV FXL parts.
Here are the key upgrades the FXL program delivers to the Super Duty:
- AEV 4” DualSport Suspension
- 40” BFG HD-Terrain tires
- 18” AEV Katmai DualSport Wheels
- HighMark Fender Flares
- AEV Stamped Steel Front Winch Bumper
- AEV High Clearance Rear Bumper
Part of the PXL package is also correcting the radius arm angle, which corrects the axle position and restores/optimizes steering geometry. Unlike the Ram PXL builds, the Ford FXL has no need for a hydraulic steering kit.
FXL Parts Details
To accommodate massive 40-inch tires, AEV has equipped the Super Duty with a 4-inch lift. The AEV 4-inch DualSport Suspension is composed of AEV-tuned Bilstein shocks, custom-rate coil springs, and optimized geometry. OEM payload and towing capacities are preserved.
Those big BFG HD tires are wrapped around 18-inch AEV Katmai DualSport Wheels. These relatively small wheels and massive rubber mean there are tons of sidewall on the tires. This helps create a comfortable ride and allows for immense traction and floatation when the tires are aired down. The Katami wheels are also beadlock-capable, to allow for extreme low air pressures and the off-road capability that provides.
Because of the wide stance this new wheel and tire package offers, AEV HighMark Fender Flares are required. These wide fenders not only look good and are legally required to keep the tires within the vehicle, but also offer full wheel articulation with minimal suspension lift and no rubbing.
Besides the big tires and flares, the biggest upgrades in the looks department are the AEV bumpers. Up front, there is an AEV Stamped Steel Front Bumper that can accommodate up to a 20k winch, integrates all ADAS sensors, and offers big, burly chassis-mounted recovery points.
It also offers auxiliary lighting mounts and can be optioned with a heavy-duty brush guard late in the year. The AEV High Clearance Rear Bumper offers improved rear clearance, burly corner protection, chassis-mounted recovery points, and optional backup lights.
The one part you might notice is missing, which is available on PXL and Bison/AEV Edition HD builds, is a snorkel. I asked AEV directly, and a representative said, “Due to how the engine compartment is laid out, it’s difficult to get to the intake in our traditional way, but it’s still being evaluated.”
Big Super Duty: Not Left Out
Starting in the fall, AEV will also start to offer 10-lug versions of the Katmai wheels for use on Ford F-450 and F-550 platforms. The front bumper is also directly compatible with the F-450 and F-550 models.
AEV FXL Turnkey Option
If you choose to have AEV build your FXL in its 20k-foot Wixom, Mich., production facility, you can get it with a few nice features you won’t get trying to build it yourself.
One is custom graphics (as seen in the renderings), which are painted on and not vinyl. You’ll also get custom AEV badging inside and out. This includes side badges, a tailgate badge, a windshield banner, embroidered headrests, and a serialized build plaque.
To top off the custom AEV serial numbered truck, it will come with 3-year/36,000-mile comprehensive AEV warranty coverage “backing the entire conversion.”
AEV FXL Debut
The AEV Ford Super Duty FXL will make its public debut at the 2026 Detroit Auto Show, which starts in just a few days. It will be mid-2026 before you’ll be able to buy a turn-key PXL or the parts to upgrade your own Super Duty.
As for pricing, well, no official word yet. But, based on my talks with the company, I’d expect the Ford FXL upgrade package to come in around where the Ram PXL does, which starts at $24,399. The Ford Super Duty AEV FXL is a new option for people who want something they can use as a daily driver, still tow and do HD truck things, and always be ready for big off-road and overland adventures.
