AEV FXL: Finally, The Ford Super Duty Gets The American Expedition Vehicles’ Treatment

With the much-anticipated (and worst-kept-secret-in-the-world) introduction of the AEV FXL Super Duty, AEV (American Expedition Vehicles) just might be the benchmark for amazingly badass heavy-duty off-road trucks. It started with proven conversions like the Ram Prospector XL, then expanded into OEM-backed programs with GM, which included the Chevrolet Silverado HD ZR2 Bison and the GMC Sierra HD AT4X AEV Edition. Those trucks showed what happens when serious off-road hardware is engineered correctly at a factory level. The missing manufacturer, however, was Ford. The AEV FXL Ford Super Duty finally completes that picture, and it’s everything we hoped it would be the from the moment AEV teased the headlight.

Forty-Inch Tires Look So Natural

There’s no easing into it. The AEV FXL Super Duty on ginormous 40-inch tires looks incredibly natural. The proportions are what stand out. The tire-to-body relationship, the ride height, the way the truck sits all look completely dialed. This is how the Super Duty should have come from the factory, if Ford engineers had no constraints.

Those 40-inch BFGoodrich HD-Terrain KT tires wrapped around 18-inch Katmai DualSport wheels fool you into thinking there was actually enough factory clearance for the meaty rollers. AEV’s HighMark fender flares frame the openings without excessive gap or awkward spacing. It looks wide, tall, and confident, the way a diesel truck built for real terrain should.

As you may have discovered, big tires are easy to sell and hard to execute. The FXL works because AEV didn’t treat 40s as a slap-on accessory. The entire truck was engineered around them. AEV’s 4-inch DualSport XP suspension with AEV-tuned Bilstein shocks exists to support that tire size while maintaining control, stability, and road manners that still make sense for a Super Duty.

Steering geometry, suspension travel, and body clearance were all addressed from the beginning, which is why the truck looks so natural on 40s. There’s no visual tension, no sense that something is being pushed beyond its limits. It looks settled and oh-so-pleasing to the eye.

Armor That Matches The Attitude

The AEV stamped steel front bumper and AEV high-clearance rear bumper accommodate the FXL Super Duty’s fitment of 40s while adding protection. Approach and departure angles improve, with the overall look staying clean and purposeful. Subtle graphics, AEV branding, and a serialized build plaque remind you this is a complete conversion.

Ford Finally Gets The Full AEV Treatment

The AEV FXL Super Duty debuts at the 2026 North American International Auto Show in Detroit, with individual components available starting in the second quarter of 2026. Alongside the Ram Prospector XL and GM’s factory AEV editions, the AEV FXL Super Duty shows what AEV does best. It takes a heavy-duty diesel truck and engineers it properly for sexy 40s (for Ford and Ram, at least). We can’t wait to see what overlanders and off-roaders do with the AEV FXL Super Duty. We anticipate bespoke camper builds and drool-worthy projects to debut throughout the year.