American Expedition Vehicles (AEV) has long been a leader in the aftermarket off-road world, delivering some of the most rugged, capable vehicles on the market. Their latest endeavor, however, marks a significant expansion into new territory—Ford. For the first time, AEV is bringing its renowned off-road expertise to Ford’s 2026 Super Duty trucks, resulting in the brand-new AEV FXL. This conversion program aims to take the already powerful Ford F-250 and F-350 trucks to the next level, with substantial upgrades that ensure these Super Duty trucks can handle extreme off-road conditions, all while keeping their on-road comfort intact.
The AEV FXL: What Makes It Special?
For those unfamiliar with AEV’s legacy, they’ve previously collaborated with Jeep, Ram, and General Motors to develop limited-edition, off-road-ready vehicles. Now, with the 2026 Ford FXL, AEV applies its skills to Ford’s Super Duty series, offering a fully integrated, ground-up conversion program. The conversion package includes a range of components designed to elevate the F-250 and F-350’s off-road capabilities without sacrificing comfort or cutting-edge technology.
The FXL designation, for those unfamiliar with Roman numerals, stands for 40, referencing the truck’s ability to accommodate a set of massive 40-inch tires—thanks to AEV’s specially designed 4-inch DualSport suspension system. This suspension setup features custom-rate coil springs, AEV-tuned Bilstein shocks, and revised geometry, all working in tandem to provide a smoother ride while maintaining the heavy-duty payload and towing capacities that the Super Duty series is known for.
Key Upgrades and Components
AEV’s conversion is designed to work seamlessly with Ford’s Super Duty trucks, ensuring they can tackle rugged terrains with ease. Here are some of the standout features of the AEV FXL conversion:
- 40-Inch Tires and DualSport Suspension:
The FXL is equipped with a 4-inch DualSport suspension system that can accommodate 40-inch tires, providing better off-road clearance without compromising on-road comfort. - AEV Stamped Steel Front Bumper:
This heavy-duty bumper not only enhances the truck’s rugged appearance but is also fully functional, capable of housing up to a 20,000-pound winch. It retains Ford’s Advanced Driver Assistance Systems (ADAS) with precise radar placement, ensuring the vehicle’s modern tech remains intact. - High Clearance Rear Bumper & Fender Flares:
AEV’s High Clearance Rear Bumper and HighMark fender flares ensure ample room for the 40-inch tires and provide extra protection for off-road excursions. - AEV Katmai DualSport Wheels:
The truck comes with 18-inch wheels that are beadlock-capable, providing added durability for tough trails. The wheels are drilled to Ford’s 8×170 bolt pattern, and they pair perfectly with 40×13.50R18 tires. - Customization Options:
The wheels also offer an optional protection ring for beadlock capabilities, and AEV plans to release a 10-lug version for F-450 and F-550 models later in the year. - Complete FXL Package:
For those wanting a fully integrated off-road truck, AEV offers the FXL as a complete turnkey package. This includes all the components mentioned above, along with BFGoodrich HD-Terrain T/A KT tires, FXL body side graphics, and special AEV branding on the tailgate and fender vents.
AEV’s First Ford Build: A Showstopper at the Auto Show
The AEV FXL won’t be available for purchase until later in 2026, but it will make its debut at the North American International Auto Show in Detroit. The show truck will feature all the standard conversion components, along with a custom interior and embroidered AEV headrests. While these interior touches won’t be standard in the production model, the show truck will offer a glimpse of what’s possible with AEV’s signature off-road modifications.
For buyers, AEV anticipates the FXL will primarily be offered as a package for premium-level Super Duty trucks, which already come with leather interiors. As with all AEV builds, the FXL will be covered by a three-year, 36,000-mile warranty, ensuring that owners can enjoy their high-performance truck with peace of mind.
Pricing and Availability
Though AEV has yet to release official pricing for the complete FXL conversion or individual components, estimates suggest that the full conversion package will likely cost around $20,000. The FXL build will be available through AEV’s authorized dealers, and the conversion will be handled at AEV’s facility in Wixom, Michigan.
For those interested in the individual parts, AEV will also offer accessories for those who wish to customize their Super Duty trucks incrementally.
A New Era for Ford Super Duty Trucks
The 2026 Ford Super Duty FXL marks a new chapter for AEV, as it branches out from its usual partners to bring its top-tier off-road expertise to the Ford brand. With its large 40-inch tires, high-performance suspension, and rugged components, the FXL is designed to dominate the toughest terrains while providing a comfortable ride on the highway. Whether you’re looking to tackle extreme off-road trails or just want a unique and powerful upgrade for your Super Duty truck, the FXL promises to deliver a robust package for any adventure.
