2022 AEV Prospector XL Review: A Ram Truck to Mine the Overlanding Market

There's trail running, and then there's overlanding. The former portends day trips or weekend jaunts; possibly longer trips with primitive tent camping. The latter conjures extended off-grid adventuring where you may need to be self-sufficient for days at a time while exploring the wilderness on logging trails, forest-service roads, and the like. American Expedition Vehicles seeks to cover the trail-runners with its Jeep Wrangler/Gladiator and Chevy Colorado offerings while offering overlanders the Ram Heavy Duty pickup-based Prospector and Prospector XL.

Founder Dave Harriton got his start stretching his dad's old TJ Wrangler in Montana, did a few more for some friends, then started American Expedition Vehicles. When the company's builds earned design kudos from Chrysler, it found Detroit-area partners to help step up its engineering game. Before long it was cranking out hits like the Jeep Hemi V-8 conversions that predated the Wrangler 392, as well as the Brute and Brute Double Cab Wrangler pickups that presaged the Gladiator. The AEV-designed, GM-manufactured Chevy Colorado ZR2 Bison Edition is a factory-orderable $5,750 option package that transforms the desert-runner ZR2 into more of a technical rock crawler. In addition to supplying parts for these GM builds, AEV upfits roughly 800 vehicles per year in its Wixom, Michigan, facility, evenly split between Jeeps (Wrangler and Gladiator) and Ram Heavy Duty pickups (2500 and 3500).

AEV offers two packages applicable to either the Ram 2500 or 3500: Prospector and Prospector XL. Both get toughened AEV bumpers, a 3.0-inch suspension lift, AEV wheels, plus interior and exterior badging and graphics. Tires are the main difference between the two packages. Base Prospectors get 37-inch tires that fit under stock fenders with Mopar flares. XLs get 40-inch tires that require the fender and rear quarter openings to be expanded by about 3.0 inches (XL is 40 in roman numerals). Choose the XL if you're looking for the ultimate rock-climber/mud-bogger; go for the entry Prospector on a 3500 for max payload capacity when fitting heavy overlanding gear like an in-bed camper. That's because AEV de-rates the rear gross-axle-weight rating from 7,000 to 6,390 pounds for the 40-inch tires, but not for the 37s (our 2500's factory RGAWR of 6,000 is unchanged with either tire). XL versions comprise the majority of AEV's Ram business, with roughly a 60/40 split between 2500/3500. They're almost all Cummins diesel-powered except for Power Wagon upfits (some folks just gotta have those diff lockers). The base Prospector package costs $15,987; the Prospector XL costs $20,999.

At the heart of this upfit is AEV's 3.0-inch DualSport suspension, with the "dual" referring to its goal of improving technical off-road prowess with no penalty to the original ride and handling. AEV accomplishes this trick by maintaining the stock springs and the original suspension geometry. To do this, it relocates the various mounting points for the suspension hardware. The front axle, for example, is articulated down and forward, increasing the wheelbase by 1.6 inches. This saves AEV having to custom make longer versions of the 40-some different Ram springs tailored to every different weight class. AEV also fits a hydraulic-assist steering upgrade to help swivel the giant tires. Our XL was upgraded further with optional AEV/Bilstein 8100 external-reservoir shocks ($2,140) designed to keep their cool and resist the fade that comes from boiling the shock fluid in prolonged hard running in a hot desert. And it all rides on a set of AEV 10- x 17-inch black Katla 10 wheels wrapped in 40 x 13.50R17 Cooper Discoverer STT Pro tires.

Perhaps the most vital piece of overlanding kit for self-preservation is a sturdy winch. AEV front bumpers are all designed to accept one, but they cost extra. Our AEV Prospector XL featured a Warn 16.5ti with synthetic rope that rang in at $2,711. Nighttime adventuring requires lighting, so we also had $2,801 worth of auxiliary LED lamps that mount to the $1,700 bumper brush guard, plus a set of rear-bumper LED lights ($594). The bed is fitted with a matching spare wheel and tire on a vertical mount ($1,736) that obscures most of the rear-window visibility and blocks the location where a rearview camera would go. We'd opt for the lay-flat spare option (there's no slinging any spare tire larger than stock underneath). A bed rack with crossbars provides a mounting point for a rooftop tent, axes, Jerry cans, etc. And finally, to fortify the underbody we added hardened differential covers front and rear ($381.50 and $409.50) and a breathable intercooler skidplate ($531.50). This all brings the estimated curb weight to within 1,000 pounds of the truck's gross rating, so some judicious expedition packing is called for (or an upgrade to the 3500). Along with some cosmetic upgrades, total AEV optional equipment came to $19,150.50, bringing the all-in price of our well-equipped Laramie to $119,194.50.

Having recently spent a year in a stock Ram 2500 Laramie Cummins, the most indelible initial impression is how loud the tires are, the sound and vibration even coming up through the steering wheel in turns. This is followed closely by how high the AEV Prospector XL sits. You'll look down on lifted Super Dutys and across at semi drivers. Getting comfortable with the size takes a few miles; sitting so high off the road dulls your sense of speed. So if your natural pace is 10 mph beyond the speed limit, you may frequently find yourself 15 or 20 over. The taller, heavier tires and added curb weight blunt the acceleration, but it's still plenty strong. The added inertia is also noticeable in braking, where stops take more pedal effort than in our long-term Ram 2500. But sure enough, the ride feels almost identical—maybe smoother, thanks to the additional mass (AEV estimates ours weighs just shy of 4.5 tons). That is, until one of these jumbo donuts hits a single-wheel bump and sends a shudder through the steering and chassis. These mud tires don't grip paved corners like the stock tires, but then the stockers can't claw through mud bogs.

Having mostly wheeled crossovers and stock Jeeps at our local ORV park, we're used to the toughest obstacles being off limits. Not for this rig! Climb any rock or plunge through any bog by simply relying on the tire-tread lugs and the Cummins torque and inertia to power through. Tough dusty ruts, sandy moguls—it doesn't matter. The Prospector XL tackled every path or obstacle with ease, or at least every path physically wide enough to accommodate it. And with the long wheelbase and gigantic turning circle, you must be cognizant of your escape route should a path prove too narrow. We were also impressed by how sturdy everything felt. The AEV Prospector XL took the harshest impacts in stride, and with no expensive sounding noises.

If you have a low-mileage current-generation Ram (or Jeep) that's never been wrecked, AEV can upfit it for you, but most builds are ordered new through AEV's online configurator and delivered through one of its 100 dealers. The dealer facilitates getting the stock truck built, shipped to AEV for the upfit, then shipped to the dealer. Upfitting typically takes about a week barring supply issues, and tires have lately been in particularly short supply. Buyers can specify unique paint—like the zinc-chromate green on AEVs four 2019 SEMA builds—but this stretches the build to 30 days and adds $13,687.

That $119,000 price includes a lot of showy bits we could do without. But the engineering is so stout we felt compelled to gin up an ideal build, starting with a strategically optioned 2500 Tradesman Cummins with Auto Level Rear Air Suspension, the Convenience Group, Uconnect 5 nav, Bed Utility Group, and the aux switches for $64,745. Then we spec'd a Prospector with 37s, the Mopar retractable steps ($2,420—they were included in our Laramie, and you need 'em!), AEV's leather and Cordura seat upgrade ($2,205), the smaller light bar ($1,024) plus the winch, intercooler skidplate, diff covers, and a few doodads for a total upfit cost of $29,196. We'd be out the door for $93,941 with the same suspension in a slightly more livable, goes nearly anywhere package with a bit more payload capacity, a quieter ride, and a slightly lower climb.