AMP Research Power Step 10-02996-13 User manual

www.amp-research.com 1/10
INSTALLATION GUIDE
IM2996 rev 11.27.06
APPLICATION LENGTH MODEL YR PART #
Ford F-150 Supercrew 2001-2003 10-02996-13
(2004 Heritage)
Designed and manufactured by AMP Research. Patent 6,830,257 / 6,641,158 / 6,834,875 / 6,938,909 / 6,942,233 / 7,007,961 Other US and worldwide
patents pending. Three-year limited warranty. Professional installation is recommended. Nationally Distributed by Bestop.
TOOLS REQUIRED
qSafety goggles
qMeasuring tape
qFlat blade screwdriver
qPhillips head screwdriver
qRight angle drill
q1/8” drill bit
q21/64” drill bit
q13mm socket
q10 mm socket
q8 mm socket
qRatchet wrench and extension
q13mm end wrench
qWire crimpers
qWire stripper / cutter
qVise grip pliers
qCorrosion inhibiter
q3/16” hex key wrench ( allen
wrench )
q5mm hex key wrench ( allen
wrench )
q4mm hex key wrench ( allen
wrench )
qElectrical tape
qWeather proof caulking ( silicone
sealer )
INSTALLATION TIME
12 3 4
SKILL LEVEL
4= Experienced
3:00 hrs
Designed and manufactured by AMP Research. Patent 6,830,257 / 6,641,158 / 6,834,875 / 6,938,909 / 6,942,233 / 7,007,961 Other US and worldwide
patents pending. Three-year limited warranty. Professional installation is recommended. Nationally Distributed by Bestop.
TECH SUPPORT 1-888-983-2206 (Press 5 for Customer Service) Monday - Friday, 8:00 AM - 5:00 PM PST

www.amp-research.com 2/10
AMP RESEARCH POWER STEP – FORD F150 SUPERCREW
IM2996 rev 11.27.06
INSTALLATION GUIDE
Attaching motor to linkage assembly
The motors need to be installed before continuing with the rest of the Power
Step install.
CAUTION: HANDLE WITH CARE.
To insure our customers receive all components with full integrity, we pack
the motors seperate from their linkage assemblies. This requires that the
installer position and fasten the motor before continuing with the install.
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 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 T30 Torx. Tighten screws to 80 in-lbs (9N-m). Do not over
torque.
zz
EXPLODED VIEW
19-03129-11 Motor
19-03179-90 Socket cap screw
19-03133-90 Washer

www.amp-research.com 3/10
AMP RESEARCH POWER STEP – FORD F150 SUPERCREW
IM2996 rev 11.27.06
5
1x2
20-03314-72
Step assembly
2x2
10-03058-11
Idler linkage assembly
3x2
10-03059-12
Motor linkage assembly
4
19-02726-91
Wire harness
19-03297-93
Controller
6
19-02727-90
Single-diode
CE
A
D
B
(A) 19-03225-11 End cap left (x1)
(B) 19-03225-12 End cap right (x1)
(C) 19-02663-90 T-nut insert (x2)
(D) 19-03236-90 Socket cap screw (x2)
(E) 19-03237-90 Nut plate (x2)
x4
NOTE: The motor is
shipped seperated from
upper mount for part
protection. Preassembly
required. See page 2.

www.amp-research.com 4/10
AMP RESEARCH POWER STEP – FORD F150 SUPERCREW
IM2996 rev 11.27.06
Front Bracket
7
19-02890-90
Double Diode
8
19-03044-90
Drill Template
9x2
16-03166-90
Rear Bracket
11 x4
19-03037-90
Hex Flange Bolt
12 x2
16-03171-90
Support Bracket
13 x6
19-02488-90
Nut U-Style
14 x8
16-02634-90
Button Head Bolt
15 x6
19-02740-90
Hex Flange Bolt
16 x8
19-02802-90
Socket Cap Screw
17
19-02992-90
Tubing
(Installation Tool)
PARTS LIST AND HARDWARE IDENTIFICATION
18 x25
19-02805-90
Cable Ties 7”
19 x2
19-03339-90
Cable Ties 11”
20 x2
19-02989-90
Bull Connector
21 x2
19-02986-90
Connecting Wire Red
22 x8
19-03021-90
Hex Nut
Rear Bracket
10
16-03165-90
Front Bracket
x2

5/10
www.amp-research.com
AMP RESEARCH POWER STEP – FORD F150 SUPERCREW
IM2996 rev 11.27.06
Install U-Nut. Drilling Rear Mounting Holes: Posi-
tion and clamp drill template as shown, (center on
U-Nut) and pilot drill mount holes with 1/8”drill bit.
Remove template and drill holes to 21/64”.
8
13
1.2”
rear of vehicle
Note: Steps 1-9 show Driver’s Side.
Install U-Nut. Drilling Forward Mounting Holes:
Position and clamp drill template as shown,
(center on U-Nut) centering the template
around stock mounting hole.
13
front of vehicle
3
Mounting Rear Brackets: Install two u-nuts if
not already present. Install support bracket and
then install Rear Bracket. Do not tighten bolts
yet.
9
12
15
Position Idler Mount at rear mount location and
bolt to bracket and drilled mounting holes.
Snug all bolts... do not fully tighten.
14
11
2
Mount Front Bracket to upper stock mounting
hole that the drill template was centered about.
10 15
Position motor linkage assembly in forward
mounting position and bolt to bracket and
drilled mounting holes. Snug all bolts... do not
fully tighten. 11
14
3
1 2
3 4
5 6

6/10
www.amp-research.com
AMP RESEARCH POWER STEP – FORD F150 SUPERCREW
IM2996 rev 11.27.06
Insert controller through loose zip ties, align zip
ties into grooves in controller and tighten. Plug
in harness making sure tabs engage completely
on controller.
Line up T-nuts of step extrusion and insert 1/4-20
bolts. You may need to use the end of the Allen
wrench to align the holes with the T-nut.
1
16
The rearward edge of the board should be
about 9.5in from rear mount. Tighten 1/4-20
bolts to 10 ft-lbs.
9.5”
Tighten all bolts of steps 3-6 to 16 ft-lbs.
Repeat steps 1-9 for the passenger side.
Mounting Controller: Under the hood in front
of the wiper fluid reservoir loop the two 11” zip
ties through the holes on radiator support sheet
metal. Start zip ties, leaving enough to insert
controller.
19
19
5
7 8
9 10
11 12

7/10
www.amp-research.com
AMP RESEARCH POWER STEP – FORD F150 SUPERCREW
IM2996 rev 11.27.06
Remove the front radiator shrowd to access clear
routing for Power Step wire harness.
Route the long harness end and power hook-up
end of Power Step wire harness along front
edge and secure with tie wraps along the way.
4
After removing Power Step harness fuse, attach
ring terminal of the red wire to the positive
battery lead and that of the black wire to the
negative battery lead.
4
Route harness end with motor connectors
down the inner side walls of truck and down
along the frame to the motorized linkages. Plug
connector into motor.
43
Pierce holes in front floor board grommets to allow
access for harness trigger wire into cab of vehicle.
Push purple trigger wires through pierced holes.
Grommet
Trigger Wire
4
After pushing/pulling wire slack through grommet,
apply some silicon sealer to hole in grommet.
Secure any loose wires with tie wraps and/or electri-
cal tape.
13 14
15 16
17 18

8/10
www.amp-research.com
AMP RESEARCH POWER STEP – FORD F150 SUPERCREW
IM2996 rev 11.27.06
Remove driver side step plate and kick panel. Of the
three connectors to the left of the parking brake pedal,
locate the top connector . Splice single diode harness
into Black with Yellow stripe wire, diode end away from
connector as shown in figure.
6
Diode
Locate harness bundle under driver sill plate, open
bundle and find Black with Light Blue stripe wire. Splice
into wire single diode harness with the diode end toward
the front of the vehicle.
6
front of vehicle
Diode
Connect Double Diode Harness to purple trigger wire
and extend each end to the blue butt connectors of
steps 19 and 20.
7
19
Extension
Wire if needed
20
Trigger Wire
On the Passenger side remove front door paneling
and locate wire bundle running out toward the door
latch as shown. Connect Single Diode Harness to
Black with Pink stripe wire with diode end heading
back toward the vehicle cabin.
66
Diode
Pass supplied red connecting wire from door to cabin
through the door hinge wire accordion. You may want
to use the supplied plastic tubing to help pass the wire
through.
20
Connect door end of red connecting wire to the blue
butt connector of step 22. Secure any loose wires
with tie wraps and/or electrical tape.
20
19 20
21 22
23 24

9/10
www.amp-research.com
AMP RESEARCH POWER STEP – FORD F150 SUPERCREW
IM2996 rev 11.27.06
Under passenger front kick panel locate bundle that
comes from the rear of the vehicle. Open the bundle and
locate the Black with White stripe wire and splice in
Single Diode Harness with the diode end toward the front
of the vehicle.
6
Diode
Connect purple trigger wire to Double Diode Harness.
Connect one open end of the harness to the red
connecting wire from the door and the other end to
the blue butt connector of
step 25.
7
Trigger
Wire
Secure all loose wires with tie wraps and/or electrical
tape.
Reinstall the fuse that was removed in step 15 and
check for proper functioning of the step. Check for
even stow position of board.
Slight adjustments to the upper mount can be made
to adjust stow positon. With the board extended,
loosen hex bolt as shown, adjust as needed, and
retighten hex bolt to 16 ft-lbs. The adjustments will be
made to either increase or decrease the gap between
the board and rocker panel when stowed. decreases gap
increases gap
#25 7
26
27 28
29

www.amp-research.com 10/10
AMP RESEARCH POWER STEP – FORD F150 SUPERCREW
IM2996 rev 11.27.06
AMP RESEARCH warrants product to be free from defects in material and workmanship, for terms specified
below, provided there has been normal use and proper maintenance. This warranty applies to the original pur-
chaser only. All remedies under this warranty are limited to the repair of replacement of any item found by the
factory to be defective within the time period specified.
If you have a warranty claim, first you must call our factory at the number below for instructions. You must
retain proof of purchase and submit a copy with any items returned for warranty work. Upon completion of war-
ranty work, if any, we will return the repaired or replaced item or items to you freight prepaid. Damage to our
products caused by accidents, fire, vandalism, negligence, misinstallation, misuse, Acts of God, or by defective
parts not manufactured by us, is not covered under this warranty.
THE WARRANTY TIME PERIOD IS AS FOLLOWS: THREE YEARS FROM DATE OF PURCHASE.
ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE
CREATED HEREBY ARE LIMITED IN DURATION TO THE SAME DURATION AND SCOPE AS THE
EXPRESS WRITTEN WARRANTY. OUT COMPANY SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGE.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of
incidental or consequential damages, so the above limitations or exclusions may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights that vary from state to state.
For further information or request for warranty work, please call toll-free 1-888-983-2206 (press 5) for
Customer Service.
The manufacturer strongly recommends that this product be professionally installed.
Failure to carefully follow the electrical installation steps could result in severe electrical shock that could harm
the installer and/or damage the vehicle.
This product is designed to enhance the appearance of the vehicle. Do not rely in any way on the components
of this product to contain occupants within the vehicle, or to protect against injury of death in the event of an
accident. Never operate vehicle in excess of manufacturer’s specifications.
WEAR SEAT BELTS AT ALL TIMES
Read and follow, precisely, all installation instructions provided when installing this product. Failure to do so
could place occupants of the vehicle in a potentially dangerous situation. After installing or reinstalling, check to
make sure it has been properly installed.
WARNING
LIMITED WARRANTY