AMP Research PowerStep Installation Guide

Installation Overview

Installation Time: 3-5 Hours (Professional installation recommended)

Skill Level: 1 2 3 4 (4 = Experienced)

Tools Required:

• ? Safety goggles
• ? Measuring tape
• ?️ 1/8", 19/64" Drill bits
• ? 10 mm socket
• ? 13 mm socket
• ? 13 mm ratchet wrench
• ? Ratchet wrench and extension
• ? Wire crimpers
• ? Wire stripper / cutter
• ? 3/16" hex key wrench (allen wrench)
• ? 4mm allen wrench
• ? Electrical tape
• ? Weather proof caulking (silicone sealer)
• ⚡ Drill Motor
• ? Heat Gun

Warranty: 5-Year Limited Warranty

AMP Research Tech Support: 1-888-983-2204 (Press 2) Monday - Friday, 7:00 AM - 5:00 PM PST

Invented, engineered and manufactured exclusively by AMP Research in the USA. May be covered by one OR MORE of the following patents: 6,641,158; 6,830,257; 6,834,875; 6,938,909; 7,055,839; 7,380,807; 7,413,204; 7,398,985; 7,584,975; 7,566,064; 7,487,986; 8,157,277; 8,408,571; 9,302,626; 9,561,751; 10,053,017; CA2463717 ©2012 AMP Research. All rights reserved. Printed in USA.

Website: www.amp-research.com

Step 1: Attaching Motor to Linkage Assembly

The motors must be attached to the rear Linkages before installation. The Driver's side motor mounts on the opposite side of the linkage as the Passenger side motor does.

Exploded View:

• Motor
• Socket cap screws
• Washers
• Motor Linkage assembly

CAUTION: HANDLE WITH CARE.

To ensure customers receive all components with full integrity, motors are packed separately from their Linkage assemblies. This requires the installer to position and fasten the motor before continuing with the installation. Please follow the instructions below and handle the assembly carefully.

CAUTION: Dropping the assembly or any excessive impact MAY cause damage to the motor.

Instructions:

1. Position the gear cover in place as shown if not already in place.
2. Seat the motor into position on the three mounting bosses. This may require an adjustment of the gear by moving the swing arms.
3. After seating into place, fasten the motor with the three motor mount screws with 4mm Hex Head. Tighten screws to 36 in-lbs (4N-m). Do not over torque.

Step 2: Parts List and Hardware Identification

Note: Some Applications require modification.

Components:

• (1) x2 Running Board assembly: Includes end caps (1 left & 1 right), T-Nut Insert (x2), S-style clips (x2).
• (2) Driver Side Motor Linkage Assembly
• (3) Passenger Side Motor Linkage Assembly
• (4) x2 Front Idler Linkage Assembly

Step 3: Hardware Identification

• (5) Wire Harness
• (6) Controller STA
• (7) OBD II Plug
• (8) x2 Motor
• (9) x2 Motor Cover
• (10) x4 LED Lamp
• (11) x8 Socket Cap Screw
• (12) x2 Posi-Lock Connector
• (13) x8 Conical Washer Bolt
• (14) x20 Cable Tie 7"
• (15) x2 Cable Tie 11"
• (16) x8 Butt Connector
• (17) x4 Grommet
• (18) Nut
• (19) x2 Posi-Tap™ (Red/Grey)

Step 4: Installing Linkages (Driver Side)

Front Linkage (Idler Linkage):

Install the Idler linkage in the First mount position at the front of the truck, for Passenger and Driver sides, using the bolts supplied (13). Remove all plastic or rubber hole plugs that are next to the linkage mounts. An extra vertical seam-sealer bead may need to be removed from the front linkage mounting surface. Torque fasteners to 16 ft-lbs. (22 N m).

Rear Linkage (Motor Linkage):

Assemble the motor to the linkage as shown on page 2, positioning the motor so the linkage is in the mid-extension position to allow the lower bolt to be installed. Install the motor linkage with provided Conical washer bolts (13) in the second to last set of holes, approximately 16" from the rear of the cab. If these holes are not present on some models, use the next set of holes forward, approximately 33" from the rear of the cab. Keep the linkage held up to the angled and vertical surfaces. Some structural adhesive remnants may need to be chipped off at the rocker seam. Torque fasteners to 16 ft-lbs. (22 N m).

Step 5: Installing Linkages (Passenger Side)

Rear Linkage (Motor Linkage):

Install the Motor linkage on the passenger side in the second to last set of holes from the rear. The motor should face the front of the vehicle. Follow the same steps as on the Driver side. Torque fasteners to 16 ft-lbs. (22 N m).

Board Installation:

Slide the front mounting T-nut into position. Place the board (1) about 5 to 6 inches from the front edge of the front door. Use fasteners (11) to attach boards, finger tighten only. Align the rear T-nut and bolt it to the rear linkage. Then tighten all 4 fasteners to 10 ft-lbs.

Fuse Removal: Remove the fuse from the Powerstep wire harness.

Step 6: Wiring and Controller Installation

Plug the main connectors (5) into the controller (6). Attach the controller to the passenger side wire harness bundle on the outside of the battery. Secure with 11" cable ties (15). Route the long wire harness leg across the truck under the edge of the cowl (zip tied through the push rivet slots on the bottom), and then down to the outside of the frame away from the exhaust and steering, securing it with cable ties (14). The other leg should go down immediately away from the exhaust to the frame area, securing with cable ties as needed. Note: On dual battery vehicles and Diesel models, the Passenger side battery is still required.

Battery Connection:

Remove the Negative terminal on the battery to prevent a CEL (Check Engine Light) when removing connectors under the dash in step 13. A loss of communication code may appear if the battery is not disconnected.

Remove the cover on the battery top box. Connect the Black wire to the battery terminal accessory stud (install under factory nut). Connect the Red wire to the stud on the positive power battery cable terminal using the included Nut (18).

Step 7: Interior Wiring

Remove the driver side door sill trim and kick panel carefully. Pull up the carpet, and poke a small screwdriver through the rubber insulation material.

Route the two trigger wires towards the rear of the vehicle above the body mounts, and up through the hole made in the rubber grommet in the previous step. Secure harness with supplied cable ties.

NOTE: Seal holes with silicone glue and cover with tape so carpet does not stick to glue.

On the Driver side, Do Not Zip-tie the Wire Harness to the Brake Lines.

Step 8: OBD Module Connection

In the driver side kick panel area, locate the bank of 8 plugs. Locate the light grey connector and the light green connector.

• On the light grey connector, locate the Light Green/Grey stripe wire in pin location 29. Use the supplied Posi-tap™ (19) and connect the blue wire from the OBD module.
• On the light green connector, locate the Green/Yellow stripe wire in pin location 19. Use the supplied Posi-tap™ (19) connector and connect the white wire from the OBD module.

See the next step for Posi-lock™ (12) install instructions.

Step 9: OBD II Install

Use Supplied Posi Twist connectors to attach the Plug and Play Module to the Harness. Attach matching colors on the harness to the wires on the module. Plug in module (7) to the OBD II port on the vehicle. Secure harness with supplied tie wraps.

Note: If the OBD II pass-thru harness (76405-01A) was purchased, see the install sheet supplied in packaging. The pass-through harness allows for an open port for other accessories.

Options:

• Direct to Port Option: Connects the Powerstep Control Module directly to the Vehicle Port.
• Pass-Through Harness Option: Uses a pass-through harness that connects between the Vehicle Port and the Powerstep Control Module, leaving the original vehicle port accessible.

Step 10: Drilling for Light Wires

On each side of the vehicle, mark the center of each door on the pinch weld and mark for drilling for the light wires in the next step. Ensure there is a clear path to the back of the pinchweld for the wire to enter.

Measure down 1/2" from the top of the pinchweld. Center punch and drill a 1/8" pilot hole, then drill a 19/64" hole through the pinch weld at the marked locations. Deburr all holes. After drilling, apply paint to the holes to prevent rusting.

Note: Recommend using a step drill to enlarge holes.

Step 11: Lamp Installation

Insert grommet (17) into drilled holes. Insert lamp (10) wires through the grommets. (Silicone lube can help wires slip through grommets.)

Affix the lamp to the rocker panel surface. Make sure the lamp is affixed to a flat, clean surface.

Using supplied butt connectors (16), connect the lamp wires: Red to Red, Black to Black. Once crimped, use a heat gun to shrink the tube.

Close and wrap with conduit and electrical tape. Secure all loose wires with cable ties, with lamp wires pulled upward to avoid any wire snagging.

Step 12: Final System Check

Reinstall the fuse to the wire harness. Check that all doors activate the Power Step and the LED lights work when doors open and close. Reinstall any remaining trim panels.

System Operation:

• Normal Operation: When the doors open, PowerStep automatically deploys from under the vehicle. When the doors are closed, PowerStep automatically returns to the stowed/retracted position. Note that there is a 2-second delay before the PowerStep returns to the stowed/retracted position.
• Correct Operation of Lights: All four lamps will illuminate upon opening any door of the vehicle. Lamps will stay on until restowing of both Power Steps or until 5 minutes has expired with the doors open. When the lights timeout after 5 minutes, they can be reilluminated by closing and opening any door of the vehicle.

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Operation and Warranty Information

Congratulations on your purchase of the genuine AMP Research PowerStep!

Power-Deployable Running Boards Operation:

• Automatic power deploy: The running boards extend down and out when the doors are opened.
• Automatic power stow: The running boards return to the stowed position when the doors are closed, with a 2-second delay.
• Automatic stop: If an object obstructs the moving running board, it will automatically stop. To reset, clear the obstruction, then open and close the door.
• Manual deployment: The running boards can be manually set in the deployed (OUT) position for access to the roof by firmly holding the step down with your foot while closing the door. Open and close the door to resume normal operation.

Maintenance:

In adverse conditions, debris like mud, dirt, and salt can become trapped in the running board mechanism, potentially causing noise. If this occurs, manually set the running boards to the deployed position and flush the front and rear hinge arms with a high-pressure car wash wand. Avoid spraying the motors directly. After washing, apply silicone spray lubricant to the hinge pivot pins. Do not apply silicone, wax, or protectants like Armor All® to the running board stepping surface.

Caution! Keep hands away when the running board is in motion.

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 component found defective. The decision to repair or replace is at the manufacturer's discretion.

This warranty specifically excludes labor. For warranty claims, call the factory 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 defective parts not manufactured by AMP Research is not covered.

Implied warranties of merchantability and fitness for a particular purpose are limited to the duration of this express warranty. AMP Research shall not be liable for incidental or consequential damages. Some states may not allow limitations on implied warranty duration or exclusion of incidental/consequential damages, so these limitations may not apply to you. This warranty provides specific legal rights, and you may have other rights that vary by state.

FOR WARRANTY ISSUES WITH THIS PRODUCT, PLEASE CALL AMP RESEARCH TECH SUPPORT 1-888-983-2204

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 also consider recycling the packaging.