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If you were getting those previous MPG numbers on E85, then you were doing outstanding. The EPA estimates are for ethanol free unleaded. E15 is a big hit and e85 is a huge hit to MPG.
Any air going through the radiator is hitting a bigger "brick" than sliding around the van. You only want as much airflow necessary for cooling. Unless you are towing or have added something like a roof top tent, the van should hardly be working going down the highway. If it's a 3.5 Ecoboost, they do make serious heat towing but if it's overheating and leaving the active shutters closed I would say you have a problem with the system.
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