American Expedition Vehicles is taking Ford’s heavy-duty lineup into territory usually reserved for custom shops, giving buyers a way to bolt on 40s without sacrificing the work-truck DNA. Its new FXL package turns a showroom-fresh Ford Super Duty into a fully engineered off-road rig that still tows, hauls, and commutes like a factory build. Instead of chasing shock value, the conversion is designed to keep the truck’s core capabilities intact while adding serious clearance and presence.
The result is a turn-key system that lets owners of 250 and 350 single rear wheel models step straight into 40-inch rubber with factory-style drivability. Rather than piecemeal lifts and trimming, the FXL kit wraps suspension, bodywork, and hardware into a cohesive package that is meant to feel like an extension of Ford’s own engineering.
What the FXL Package Actually Does to a Super Duty
The defining mission of the FXL program is simple: fit 40-inch tires on a Ford Super Duty the right way, with geometry and hardware that can handle the extra leverage and weight. According to The AEV FXL overview, the conversion is built around that 40-inch target while preserving stability, towing, and long-distance use as Ford intended. That means the lift height is kept reasonable, the steering and suspension are recalibrated, and the truck’s core structure is left to do what it was designed to do.
Rather than a generic lift, the FXL is a Turn Key Super Duty, Built The AEV Way, with a curated set of parts that are designed to work together. The company describes the FXL conversion as a fully built Super Duty centered on a comprehensive suspension and body package, not a menu of à la carte add-ons. At the heart of that approach is a family of AEV-engineered components, with the brand noting that, At the foundation of every FXL conversion is a family of parts tuned to deliver both capability and durability, a point underscored in its own At the product description.
How AEV Makes 40s Work in the Real World
Running 40s on a three-quarter-ton or one-ton truck is not new, but doing it with OEM-like manners is where the FXL tries to stand apart. The AEV FXL program engineers the Ford Super Duty to run 40-inch tires while preserving stability, towing, and daily usability, as detailed in a technical breakdown of Ford Super Duty changes. That focus shows up in choices like a roughly 4-in lift, which testers note is not especially dramatic on such a large platform, keeping center of gravity in check while still clearing the big tires, as seen in a detailed walkaround video.
Bodywork is just as critical as suspension when you are packaging 40s. The FXL relies on enormous fender flares from HighMark to create the necessary opening, while revised bumpers and supporting hardware manage approach and departure angles. Reporting on the package notes that the former was accomplished thanks to HighMark’s flares and the latter through a tailored bumper system that can even bear the up-fitter’s branding, details highlighted in coverage of the FXL hardware. The result is a truck that looks purpose-built rather than hacked together, with tire clearance that holds up when the suspension is fully articulated.
From Dealer Lot to Turn-Key FXL
One of the biggest shifts with this program is how accessible it is. Starting this year, buyers will be able to order a new Ford Super Duty F-250 or F-350 single rear wheel truck with the FXL treatment directly through participating dealers, rather than chasing aftermarket shops after the fact. That dealer-integrated path, described in detail in a first look at the Starting rollout, positions the package as a near-factory option for customers who want serious off-road capability without giving up warranty support or financing convenience.
AEV itself frames the program as a major step into the Ford Super Duty segment. In its launch materials, the company states, Introducing the AEV FXL, an exciting new turn-key conversion for the Ford Super Duty, built from a brand-new line of parts tailored to this platform, language repeated across its Introducing the AEV announcement and mirrored in a companion post that highlights how the package will be available through its global dealer network for the Ford Super Duty line.
AEV’s First Blue Oval Flagship
For AEV, the FXL is more than just another package, it is a statement of intent in the Blue Oval world. Coverage of the debut notes that the FXL is the first Blue Oval rig to get the company’s full treatment, with AEV’s First Turn Key Ford Is Serious Business positioning it as a flagship for future collaborations. That same reporting describes The FXL as a serious off-road build that still respects what Ford’s heavy-duty trucks are known for, a point underscored in analysis of the Blue Oval partnership.
Even the name is a nod to the tire size at the heart of the project. Observers have pointed out that, for those who remember their Roman numerals, XL stands for 40, a neat reference to the 40-inch rubber that defines the Ford FXL Super Duty package. That detail, highlighted in a first-drive look at the Ford FXL Super, captures the straightforward promise behind the badge: a heavy-duty truck that can wear 40s with the same confidence it tows a trailer or hauls a load.
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