AMP Research PowerStep XL Installation Guide

Product Information

Application: Ford Bronco 4 Door

Model Year: 2021-2022

AMP Part #: 77140-01A

Manufacturer: AMP Research, USA

Warranty: 5-Year Limited Warranty

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

Skill Level: 4 (Experienced)

Tools Required

• Safety goggles
• Measuring tape
• 10 mm socket
• 13 mm socket
• Ratchet wrench and extension
• Wire crimpers
• Wire stripper / cutter
• 3/16" hex key wrench (allen wrench)
• 4mm hex key wrench (allen wrench)
• Electrical tape
• Weather proof caulking (silicone sealer)
• Silicone spray
• 5/32" Allen Key

Parts List and Hardware Identification

The following components are included in the kit:

• Running Board assembly (2)
• End caps (1 left & 1 right)
• T-Nut Insert (2)
• S-Style clips (2)
• Rail Assembly (2)
• Motor Linkage assembly Driver (1)
• Motor Linkage assembly Passenger (1)
• Idler Linkage assembly (2)
• LED Light Bracket (4)
• Upper Mount Spacer (4)
• Cable tie (7") (20)
• Cable tie (11") (2)
• Wire harness (1)
• Controller STA (1)
• M10 Hex Flange Bolt (8)
• M8 Hex Bolt w/ Conical washer (8)
• M6 Flange Bolt (4)
• Socket Cap Screw (8)
• 5/16-18 Carriage Bolt (12)
• 5/16-18 Flange nut (12)
• LED Lamp (4)
• Butt Connector (8)
• ODB II Plug (1)
• M8 Head Hex Bolt (4)
• Motor (2)
• Motor Cover (2)
• Cinch Fastener (6)
• Posi-Lock™ (2)
• Posi-Tap™ (Red) (2)

Installation Steps

Step 1: Attaching Motor to Linkage Assembly

CAUTION: HANDLE WITH CARE.

Motors are packed separately from linkage assemblies. Position and fasten the motor before proceeding. Handle the assembly carefully to avoid damage to the motor.

1. Position the gear cover if not already in place.
2. Seat the motor onto the three mounting bosses. This may require adjusting the gear by moving the swing arms.
3. Fasten the motor with three 4mm Hex Head motor mount screws. Tighten screws to 36 in-lbs (4 N-m). Do not over-torque.

Step 2: Locating Linkage Mounts

• Front Idler Linkage: Locate the front idler linkage position. Remove any plastic plugs to expose threads.
• Rear Drive Linkage: Locate the rear drive linkage position. Remove any plastic plugs to expose threads.

Step 3: Attaching Brackets

• Attach bracket (27) using M10 Hex Flange Bolts (8). (Driver side shown)
• Attach bracket (28) using M10 Hex Flange Bolts (8). (Driver side shown)

Step 4: Preparing the Rail Assembly

Insert 6 Carriage bolts (12) into the slot on the rail (2) from either end. Add Light Bracket (14) onto the 3rd and 4th bolts. Insert Flange nut (13) onto the bracket tab to attach light brackets (14) as shown. Leave loose for adjustment.

Driver side shown.

Step 5: Mounting the Rail Assembly

Set the rail into position, centering it in the rocker panel area. Starting with the rear bracket, work towards the two front brackets. Insert Flange nut (13) to the bolts to attach the rail to the brackets. Torque 4x M10 Flange Nuts (13) to 16 ft-lbs, starting from the rear of the vehicle. Note: Do not torque nuts holding light brackets; they will be tightened later.

Step 6: Mounting Linkages

• Mount the front drive linkage onto the rear location on the driver side. Thread supplied M8 Hex bolts (9) into the front drive linkage.
• Repeat for the Front idler linkage. Do not tighten yet.
• Install provided Spacer (15) and M6 Bolt (10) into the upper mount on both Drive and Idler linkages. Do not tighten.

Step 7: Securing the Rail

Slide the mounting T-nut into position. Center the board in the rail pocket. Tighten Socket Cap screws (11) to 10 ft-lbs.

Step 8: Torqueing Linkage Bolts

• Using a 13 mm socket, torque linkage bolts (4x 9) from step 5 to 16 ft-lbs.
• Using a 10 mm socket, torque linkage spacer bolt (2x 11) from step 6 to 8 ft-lbs.
• Cycle the board to verify deployment under its own weight.

Step 9: Wiring - Controller Installation

Remove fuses from the Power Step Wire Harness (6). Mount the controller using supplied zip ties (17) to harness (6) in front of the battery. Connect positive leads from the harness: Red to the positive battery terminal and Black to the negative battery terminal.

Step 10: Wiring - Harness Routing

Route the two wire harness legs down over to each wheel well. The long leg runs to the passenger side, and the short leg runs to the driver side. Ensure the loom is free from steering and exhaust components. Secure the harness with Zip Ties (16).

Step 11: Wiring - Firewall Pass-Through

Locate the oval grommet on the driver side of the firewall. Push it out. Make a small hole in the grommet and thread the trigger wires into the cab of the vehicle.

Step 12: Wiring - CAN Bus Connections

Locate the following wires and connect using supplied Posi-Tap™ (26) to the corresponding wire colors:

Step 13: OBD II Module Connection

Use supplied Posi-Lock™ (25) connectors to attach the Plug and Play Module to the Harness. Attach matching colors on the harness to the wires on the module. Plug the module into the vehicle's OBD II port. Secure the harness with supplied tie wraps.

Note: If the OBD II pass-thru harness (76404-01A) was purchased, refer to the installation sheet included with that product. The pass-through harness provides an open port for other accessories.

Step 14: Motor Connection

On the driver side, run the Wire Harness leg down and along the underside of the vehicle floor and frame to the rear Drive Linkage. Connect the harness to the motor and secure the harness with tie wraps.

Note: The motor on the driver side faces the front of the vehicle, and the passenger side motor faces towards the rear of the vehicle.

Step 15: LED Lamp Installation

Affix the LED Lamp (18) to the Light Bracket (14) on the rail. Slide the bracket into the desired position and tighten using a 5/32" Allen key.

Step 16: Connecting LED Lamps

Using supplied butt connectors (19), connect the lamp wires: Red to Red, Black to Black. After crimping, use a heat gun to shrink the tube. Close and wrap the conduit with electrical tape. Secure all loose wires with zip ties (16). Pull lamp wires upward to avoid snagging.

Step 17: Final System Check

Check that all doors activate the PowerStep and the LED lights function correctly when doors open and close.

• Normal Operation: When doors open, PowerStep deploys automatically. When doors close, PowerStep retracts with a 2-second delay.
• Correct Operation of Lights: All four lamps illuminate when any door is opened. Lamps remain on until Power Steps are stowed or for 5 minutes. Closing and opening a door will re-illuminate the lamps after the 5-minute timeout.

Reinstall any remaining trim panels.

Operation

Power-Deployable Running Boards Operation: AMP Research PowerStep running boards automatically move when doors are opened to assist entering and exiting the vehicle.

• Automatic Power Deploy: Running boards extend down and out when doors are opened.
• Automatic Power Stow: Running boards return to stowed position when doors are closed, with a 2-second delay.
• Automatic Stop: If an object obstructs the moving running board, it will stop automatically. To reset, clear the obstruction and open/close the door.

Manually Set in Deployed (OUT) Position: Firmly hold the step down with your foot while closing the door. To resume normal operation, open and close the door.

Maintenance: In adverse conditions, flush the hinge arms with a high-pressure car wash wand if debris (mud, dirt, salt) causes noise. Avoid spraying motors directly. Apply silicone spray lubricant to hinge pivot pins after washing. Do not apply silicone, wax, or protectants like Armor All® to the stepping surface.

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

Warranty Information

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 its components, at the manufacturer's discretion. Labor is excluded.

To make a warranty claim, call AMP Research Tech Support at 1-888-983-2204 for instructions. Proof of purchase is required.

This warranty does not cover damage caused by accidents, fire, vandalism, negligence, misinstallation, misuse, Acts of God, or defective parts not manufactured by AMP Research.

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

Contact & Registration

AMP RESEARCH TECH SUPPORT: 1-888-983-2204 (Press 2) Monday - Friday, 7:00 AM - 5:00 PM PST

Product Registration: Register your product at www.amp-research.com/productregistration for faster service and product updates. Registration ensures your purchase receipt and product info are in their system, facilitating easier warranty claims and access to customer service.

View Other Products: Visit www.amp-research.com to see other AMP Research products for your vehicle.

Important Warning

WARNING: Read and precisely follow all provided instructions during installation. Failure to do so could place vehicle occupants in a dangerous situation. After installation or reinstallation, re-check to ensure the product is properly installed.