AMP Research PowerStep Installation Guide

Tools Required

• ✔️ Safety goggles
• ✔️ Measuring tape
• ✔️ Flat blade screwdriver
• ✔️ Power Drill
• ✔️ 9/32" drill bit
• ✔️ 13 mm socket
• ✔️ 10 mm socket
• ✔️ Ratchet wrench and extension
• ✔️ 13mm end wrench
• ✔️ Wire crimpers
• ✔️ Wire stripper / cutter
• ✔️ 3/16" hex key wrench (allen wrench)
• ✔️ 5mm hex key wrench (allen wrench)
• ✔️ 4mm hex key wrench (allen wrench)
• ✔️ Electrical tape
• ✔️ Weather proof caulking (silicone sealer)
• ✔️ Silicone spray

Parts List and Hardware Identification

Parts:

• 1 x2 Running Board assembly (includes End caps (1 left & 1 right), T-Nut Insert (x2), S-style clips (x2))
• 2 x2 Idler Linkage assembly
• 3 x2 Motor Linkage assembly
• 4 Wire harness
• 5 Controller STA
• 6 x2 Motor kit

Hardware:

• 7 x2 Cable Bracket (Used on Silverado and Sierra Heavy Duty Only)
• 8 Rubber
• 9 Brake Cable Ring
• 10 x5 Hex Bolt with Conical Washer
• 11 x6 M5 Socket Cap Screw
• 12 x5 Threaded nut
• 13 x4 Hex Bolt with Conical Washer
• 14 x6 M5 Washer
• 15 x4 U-nut
• 16 x8 Socket Cap Screw
• 17 x20 Cable tie (7")
• 18 Tubing (Installation Tool)
• 19 x2 Cable tie (11")
• 20 x4 Posi-Tap™
• 21 Grommet
• 22 Cable Bracket
• 23 x4 LED Lamp
• 24 x8 Butt Connector

Installation Steps

Step 1: Attaching Motor to Linkage Assembly

The motors must be attached to the Linkage assemblies before continuing the installation process. Position the gear cover if not already in place. Seat the motor onto the three mounting bosses of the linkage assembly, adjusting the gear by moving the swing arms if necessary. Fasten the motor with the three motor mount screws using a 4mm Hex Head. Tighten screws to 36 in-lbs (4 N-m). ⚠️ CAUTION: Handle with care. Dropping the assembly or excessive impact may cause damage to the motor.

Step 2: Front Idler Linkage Installation

For 2007-2010 HD 2500 and 3500 models, remove the forward-most parking brake cable guide and replace it with the new guide (7). The factory bracket may need bending or cutting. For other vehicles, skip to Step 4. For Short Bed trucks, complete Step 2 only. For Long Bed trucks, complete Steps 2 and 3. Install the front idler linkage. Thread a supplied bolt (10) about halfway into the first sheetmetal tab/hole from the front. Place the linkage over the bolt. Tighten the lower bolt (10) to 16 ft-lbs (22 N-m). Finger tighten nut (12) onto bolt (10). Install bolt (13) and torque to 16 ft-lb (22 N-m). Finally, torque the lower nut (12) to 16 ft-lb (22 N-m), using a wrench to hold the lower bolt in place. Install plastic brake cable ring (9) in the rear of the middle body mount and the new parking brake cable guide (22) in the existing frame hole. Install nut and washer on the back side of the frame rail.

Step 3: Rear Drive Linkage Installation

Install the driver side motor linkage into the fourth sheetmetal tab/hole from the front, ensuring it clears the parking brake cable. For Crew Cabs, this is approximately 26 inches from the back of the cab. For Extended Cabs, it's approximately 11 inches from the back of the cab. Set the linkage into the second to last sheetmetal tab/hole from the rear. Use supplied bolt (10) and nut (12) to hold in position. Install bolt (13) into the upper mounting hole and snug both bolts. Torque the upper bolt (13) to 16 ft-lbs (22 N-m) first, then torque the lower bolt (10) and nut (12) to 16 ft-lb (22 N-m). Repeat linkage installation on the passenger side. Install rear linkages with U-nut (15) as shown.

Step 4: Mounting the Controller and Battery Connection

Using two 11" cable ties, mount the controller to the support arm next to the battery. For diesel engines, mount behind the support arm. For Hybrid models, mount on the driver's side of the engine compartment. Remove the power fuse. Attach the power lead (RED wire) to the positive pole on the battery. ⚠️ CAUTION: Do not ground wrench when engaged with nut. Attach the ground lead to the negative battery pole.

Step 5: Wire Routing

Gas Engine Wire Routing: Route the long end of the wire harness above the engine and down through the driver's side wheel well. Zip tie the harness to cowling clips on the firewall. Route the short end down the passenger's side.

Hybrid Models Wire Routing: Route the long end of the wires down through the passenger's side wheel well and the short end down the driver's side.

Diesel Engine Wire Routing: Route the long end of the wire harness under the intake and along the factory engine harness to the driver's side wheel well. Route the short end down the passenger's side. Secure all routed wires with zip ties.

Step 6: Interior Wire Routing

Route the wire harness along the frame and back towards the rear linkage, securing with zip ties. Poke a hole through the rubber grommet near the front door on the underside of the floor panel using a small Phillips screwdriver. Push both wires through the hole. Seal holes with silicone glue and cover with tape so the carpet does not stick to the glue.

❗ IMPORTANT: Steps 14 and 15 are for Crew Cab trucks only. Light Blue and Green wires are only used with Crew Cab trucks.

Pull up the carpet and thread both wires through the floor panel. For all vehicles except Crew Cabs, skip to Step 18. For Crew Cab trucks, carefully remove wire wrap on the driver's side to find the LIGHT BLUE wire with a BLACK STRIPE. On the passenger's side, find the GREEN wire with a BLACK STRIPE, located rear of the "T" junction where wires cross under the front seat. Using the supplied Posi-Tap™ connector, splice the shorter trigger wire into the identified vehicle wire. If not used, tape off the short wire.

Posi-Tap™ Instructions: Insert connector, tighten. Strip 3/8" wire, insert and tighten.

Step 7: Accessing Vehicle Wiring and Door Panel Removal

For model years 2007-2010, locate and inspect the Body Control Module (BCM) above the brake pedal under the dashboard. The BCM is the only module with a pink connector. Check for the front door ajar signal wires: Grey/Black and Tan/White. If these wires are not present, the front door panels must be removed.

Vehicles without these wires in the BCM, or Hybrid models, should proceed to Step 20. Remove the driver side kick panel and open the loom wrapped in grey or black tape to access the Grey/Black stripe wire. In the passenger side kick panel, find the Tan/White stripe wire in the loom wrapped in green or black tape. Connect the Power Step Grey/Black wire to the vehicle's Grey/Black wire and the Power Step Tan/White wire to the vehicle's Tan/White wire. Proceed to Step 27.

If door panels need removal: Remove plastic trim on the door near the mirror attachment. Carefully pry up the window/door lock switch plate and remove all plugs from the switchplate. To remove the door panel, pry back the tab on the door lock, then pry off plastic covers by the handle and door latch. Remove the three door bolts and then pry loose all panel fasteners.

Step 8: Door Wiring and LED Lamp Installation

Remove the door latch cable from the door panel. Pull back the door weather guard, unbolt the speaker, and unplug it. Thread the plastic tube (18) through the accordion and into the door. Feed the longer wire from Step 13 through the tube into the door and pull it out on the door side. Route the wire along the harness to the switchplate.

For 2007-2009 Models: Locate the brown plug in the doors. Using a supplied Posi-Tap™ connector, splice into the trigger wire: Driver's side: Grey/Black wire; Passenger's side: Tan/White wire. (Note: On Hybrid models, trigger wire colors may not match due to a flipped wire harness.)

For 2010-Current Models: Locate the loom running across the top of the door panel. Carefully remove wire wrap and locate the following wires: Driver's side: Grey/Black wire; Passenger's side: Tan/White wire. ⚠️ Caution: Zip tie trigger wires to avoid snagging in the window linkage.

Reassemble the door and replace plugs; they are essential for Power Step operation. On each side of the vehicle, measure from the front edge of the door line on the pinch weld to the specified lengths for LED light placement: 22" for the front LED Light and 65" for the rear LED Light.

Affix the LED lamp (23) to the rocker panel surface. Ensure the surface is clean and flat. There is a step down midway across the surface; affix the lamp just outside of this step down. Using supplied butt connectors (24), connect the lamp wires: Red to Red, Black to Black. Use a heat gun to shrink the tube. Close and wrap conduit with electrical tape. Secure all loose wires with cable ties. Pull lamp wires upward to avoid snagging.

Step 9: Final System Check

Reinstall the fuse. Check that all doors activate the Power Step and the LED lights function correctly when doors are opened and closed. Reinstall any remaining trim panels.

Normal Operation: When doors open, PowerStep automatically deploys. When doors close, PowerStep automatically returns to the stowed position with a 2-second delay.

Correct Operation of Lights: All four lamps illuminate upon opening any door. Lamps stay on until Power Steps are stowed or 5 minutes elapse with doors open. Lights can be re-illuminated by closing and opening any door.

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5-YEAR LIMITED WARRANTY

AMP Research warrants this product to be free from defects in material and workmanship for FIVE (5) YEARS FROM DATE OF PURCHASE, provided there has been normal use and proper maintenance. This warranty applies to the original purchaser only. Remedies are limited to repair or replacement of the product or defective component part. Labor is specifically excluded. For warranty claims, call AMP Research Tech Support at 1-888-983-2204 for instructions. Proof of purchase is required. Damage caused by accidents, fire, vandalism, negligence, misinstallation, misuse, Acts of God, or non-AMP Research parts is not covered.

Implied warranties are limited to the duration and scope of the express warranty. AMP Research is not liable for incidental or consequential damages. Some states may not allow limitations on implied warranty duration or exclusion of incidental/consequential damages.

⚠️ WARNING: Be sure to read and precisely follow the provided instructions when installing this product. Failure to do so could place vehicle occupants in a potentially dangerous situation. After installing or reinstalling, re-check to ensure the product is properly installed.

The material your product is made from can be recycled. Please consider recycling the packaging.