American Expedition Vehicles Puts The Ford Super Duty On 40s With Its New FXL Platform

American Expedition Vehicles has built a strong reputation by taking already-capable trucks and turning them into properly engineered, beefed-up adventure machines. The company has done it with the Ram Prospector XL, and it has done it with GM through factory-backed trucks like the Silverado HD ZR2 Bison and the Sierra HD AT4X AEV Edition. Now, Ford Super Duty fans finally have something to point at. Yes, Ford’s F-Series hefty hauler has finally gotten the AEV treatment.

The AEV FXL gives the new Ford Super Duty a full turn-key conversion aimed at off-roaders, overlanders, and anyone who wants a trail-ready heavy-duty truck (without that backyard hack-job feel).

Built As A Complete System

What makes the FXL interesting is that AEV did not just bolt on a few aggressive parts and call it finished. The conversion is based around a full lineup of AEV-engineered components designed to work together.

As you can imagine, cohesivity is important for a truck this big. Once you start adding height, tire size, armor, and weight, everything has to play nicely together. Suspension, clearance, wheel fitment, and body protection all need to be part of the same conversation. As with its other builds, this is where AEV usually shines, and the FXL follows that same formula. In the end, it looks factory—but it’s far from it.

Yes, It Runs 40s

The headline feature is hard to miss. The AEV FXL rides on 40×13.5R18 40-inch BFGoodrich HD-Terrain KT tires mounted on 18-inch AEV Katmai DualSport wheels. On paper and in practice, fitting 40s on a Super Duty is challenging; the end result looks surprisingly natural and right. From the factory, 35s are the biggest tire option for the Super Duty.

A big part of that comes from AEV’s HighMark fender flares, which help open up the wheel arches and give the truck a balanced stance. It does not look like the tires were squeezed in as an afterthought. It looks like the truck was built around them from day one (which it kind of has to be to fit that much tire).

Suspension And Armor To Match

Helping manage that tire package is AEV’s 4-inch DualSport XP suspension with AEV-tuned Bilstein shocks. The goal is not just extra ride height. It is about keeping the truck controlled on off-road terrain while still making sense on the road.

The FXL also features a stamped-steel front bumper and a high-clearance rear bumper, giving the Super Duty better trail protection and improved approach and departure angles. A graphics package, AEV branding, and a serialized build plaque round out the conversion.

A Big Move For Ford Fans

The AEV FXL made its public debut at the 2026 North American International Auto Show in Detroit. Individual components were slated to become available through AEV’s global dealer network beginning in Q2 2026.

For Super Duty owners and fans who have been patiently waiting for AEV to bring its heavy-duty off-road formula to Ford, the FXL hits the mark. We anticipate the AEV FXL will be a popular build platform in the overland scene.