AMP Research Power Step 77121-01A User manual

www.amp-research.com 1/11 IM77121 rev 5.1.19
INSTALLATION GUIDE
3-5 Hours
Professional installation recommended
Invented, engineered and manufactured exclusively by AMP Research in the USA. May be covered by one of the following patents:
6,641,158; 6,830,257; 6,834,875; 6,938,909; 7,055,839; 7,380,807; 7,398,985; 7,584,975 ©2012 AMP Research. All rights reserved.
Printed in USA.
TOOLS REQUIRED
qSafety goggles
qMeasuring tape
q10 mm socket
q13 mm socket
q1/2” socket
qRatchet wrench and extension
qWire crimpers
qWire stripper / cutter
q 3/16” hex key wrench (allen wrench)
q4mm hex key wrench ( allen wrench )
qElectrical tape
qWeather proof caulking (silicone sealer)
qSilicone spray
INSTALLATION TIME
12 3 4
SKILL LEVEL
4= Experienced
AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday - Friday, 6:00 AM - 5:00 PM PST
APPLICATION AMP Part #
Jeep Wrangler JK 2Dr 2007-2018 77121-01A
5-Year Limited Warranty
WARRANTY

www.amp-research.com 2/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
A A
B B
2
2
1
1
WEIGHT:
jeep jk PSXL die cast linkage assembly
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN
THIS DRAWING IS THE SOLE
PROPERTY OF <COMPANY NAME >.
ANY REPRODUCTION IN PART OR AS
A WHOLE WITHOUT THE WRITTEN
PERMISSION OF <COMPANY NAME>
IS PROHIBITED.
COMMENTS:
SHEET 1 OF 1
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
DATE
NAME
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
ANGULAR: MACH BEND
TWO PLACE DECIMAL
THREE PLACE DECIMAL
NEXT ASSY
USED ON
APPLICATION
DO NOT SCALE DRAWING
FINISH
MATERIAL
REV.
A
DWG. NO.
SIZE
SCALE:1:8
CAUTION: HANDLE WITH CARE.
To ensure our customers receive all components with full integrity, we pack the motors separate 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 4mm Hex Head. Tighten
screws to 36 in-lbs (4N-m). Do not over torque.
EXPLODED VIEW
• Motor
• Hex Head Bolt

www.amp-research.com 3/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
(A) End cap left (x1)
1x2
Running board assembly
D
B
(B) End cap right (x1)
(C) T-nut insert (x2)
(D) Socket cap screw (x2)
(E) End cap wedge right (x1)
(F) End cap wedge left (x1)
A
CE
F
Cut Dimension
4
Motor Linkage assembly
Passenger
5
Idler Linkage assembly
x2
2
Rail Assembly
x2
3
Motor Linkage assembly
Driver

www.amp-research.com 4/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
Socket Cap Screw
12 x8
Cable tie (11”)
21 x2
Cable tie (7”)
20
x20
10
5/16 Button
Head Bolt
x8
22
Butt Connector
x8
11 x4
M6 Flange Bolt
Upper Mount
Spacer
18 x4
5/16-18
Carriage Bolt
13 x8
17 x8
Washer
15 x12
M8 Hex Bolt w
Conical washer
5/16-18
Flange Nut
16 x28
6
Wire harness
7
Controller STA
8
Posi Tap
x2
14
M8 Head Hex Bolt
x4
9x12
5/16 Flange Bolt
19 x4
U nut

www.amp-research.com 5/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
23
LED Lamp
x4 24
LED Light Bracket
x4
Linkage mounting
Bracket (Driver Side)
29 x2 Linkage mounting Bracket
(Passenger Side)
30 x2
28
Motor Cover
x2
26
CRH Motor
x2 27
Cinch Fastener
x6
25
Support Tab
x4

www.amp-research.com 6/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
Assemble Support tab(25) to Linkage mounting bracket
with supplied bolts(9) and nuts(16). Torque to 16ft-lbs.
Next using ange bolt(9) and nut(16) thru support tab in
bracket and tighten to 16ft-lbs.
Set bracket in place. Start with Button head bolts(10) thru
pinch weld with ange nuts(16). Snug into position, start
rear mounting bolt in u-nut using captive washer bolt(15).
Note: Use right facing brackets on driver side. Mirror for
passenger side.
Set Rear Linkage mounting bracket into position.
Follow same mounting steps as step 3.
12 10
9 &12
Insert U nut into position for front Idler Linkage mounting position.
19
19
Install U nut under vehicle, middle of rear door for
front motor linkage as shown. (Some vehicles with
factory steps may already include this u-nut).
Front of vehicle passenger side
1
2
4
3

www.amp-research.com 7/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
Install provided spacer (18) and M6 bolt (11) into upper mount as shown on both the drive and idler
linkages. Do not tighten.
Slide mounting T-nut into position. Center board in rail pocket. Tighten fasteners to 10 ft-lb
18 11
15
1
234
5
6
7
Slide 4 carriage bolts(13) into rail pocket of
driver side rail. Adjust bolts and slide over
brackets. Use supplied ange nuts and attach
rail to brackets. Center rail between body rocker
and torque 4 ange nuts to 16 ft-lbs. Assemble
Flange bolt(9) with nut(16) thru support tab on
bracket as shown. Torque to 16ft-lbs.
6
7
5

www.amp-research.com 8/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
Remove fuses from Power Step Wire Harness.
7
6
Install controller on passenger side at rewall.
Secure with 11” cable ties. Connect Red wire
to positive battery terminal and Black wire to
negative battery terminal.
76
Route longest leg of wire harness across re wall to driver side and under vehicle outside of frame
rail. Route shortest leg of wire harness down re wall and outside of frame rail on passenger side.
1
12
10 11
Using a 13mm socket Torque linkage bolts 4x
(15) from step 3 to 16 ft-lbs. Next use a 10mm
socket, torque linkage spacer bolt 2x (11) from
step 6 to 8 ft-lbs. Once linkages are tight cycle
board to verify steps deploy under own weight.
Attach motor to linkage. Using a 13mm wrench
Torque to 36 in-Lbs.
8 9

www.amp-research.com 9/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
Lift carpet. Slit rubber grommet and pass trig-
ger wires through grommet in oor into pas-
senger compartment.
Remove passenger side front door sill.
Insert Tighten
Strip 3/8” Insert and
Tighten
Posi-Tap™ instructions
Route Violet wire under carpet to driver side
door sill and connect to violet wire coming
from door as shown. Note: For door removal
attach posi tap on chassis side of door
harness.
Remove driver side door sill and pull up carpet.
Use Posi-Tap connectors to connect Power Step
trigger wires to like colored wires in the factory
system as shown: Violet/White wire in loom coming
from front door, Violet/Yellow and Violet/Grey are
not used tape o󰀨 ends. Note: For door removal
attach posi tap on chassis side of door harness.
5
13
1
17
5
5
18
1
15 1
16
14

www.amp-research.com 10/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
Using supplied butt connectors(22), connect the lamp wires. Red to Red, Black to Black. Once
Crimped use heat gun to shrink tube. Close and wrap conduit with electrical tape. Secure all loose
wires with cable ties. Pull lamp wires upward to avoid any wire snagging.
A󰀩x LED light bracket assembly to rail. Mount
front light rearward of front linkage and mount
rear light just forward of rear linkage.
A󰀩x LED lamp (23) to LED Bracket (24) as
shown.
21
22
1
20
5
19
On driver side, run Wire Harness leg down and along underside of the vehicle oor and frame
to front Drive Linkage. Connect harness to motor and secure harness with tie wraps. Route
remainder of wire harness towards rear linkage assembly for LED lights. Repeat step on
passenger side.
26 28
6
28
27

www.amp-research.com 11/11 IM77121 rev 5.1.19
AMP RESEARCH POWERSTEPTM – Jeep Wrangler JK
Reinstall Fuses from Powerstep Wire Harness.
CORRECT OPERATION OF LIGHTS: All four lamps will illuminate upon opening any door of 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 reillumintated by closing and opening any door of
vehicle.
FINAL SYSTEM CHECK
Check that all doors activate the PowerStep and the LED lights work when doors open and close.
NORMAL OPERATION: When the doors open, PowerStep automatically deploys from under the vehicle.
When the doors are closed, PowerStep will automatically return to the stowed/retracted position. Note that
there is a 2-second delay before the PowerStep returns to the stowed/retracted position.
Check that all doors activate the Power Step and the LED Lights work when doors open and
close. Reinstall any remaining trim panels.
6
37
23
24

Automatic power deploy:
The running boards will extend down and out when the doors are opened.
Automatic power stow:
The running boards will return to the stowed position when the doors are closed. There will be a 2-second
delay before the running boards move to the stowed position.
Automatic stop:
If an object is in the way of the moving running board, the running board will automatically stop.
To reset, clear any obstruction, then simply open and close the door to resume normal operation.
Manually set in the deployed (OUT) position for access to the roof:
your foot while at the same time closing the door. To resume normal operation, open and close the door.
Maintenance: In adverse conditions, debris such as mud, dirt, and salt may become trappedin the running
board mechanism, possibly leading to unwanted noise. If this occurs, manually set the running boards to
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.
™Congratulations on your purchase of the
genuine AMP Research PowerStep!
Here’s what you should know...
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. All remedies under this warranty are limited to the repair replacement of the product itself, or the repair
or replacement of any component part thereof, found by the factory to be defective within the time period specied. The
decision to repair or replace is wholly within the discretion of the manufacturer.
for instructions. You must retain proof of purchase and submit a copy with any items returned for warranty work. Upon
completion of warranty work, if any, we will return the repaired or replaced item or items to you freight prepaid. Damage
to our products caused by accidents, re, vandalism, negligence, misinstallation, misuse, Acts of God, or by defective parts
not manufactured by us, is not covered under this warranty.
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. OUR 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 specic
legal rights, and you may also have other rights that vary from state to state.
FOR WARRANTY ISSUES WITH THIS PRODUCT PLEASE CALL AMP RESEARCH CUSTOMER SERVICE 1-888-983-2204
5-YEAR LIMITED WARRANTY
WARNING
Be sure to read and precisely follow the provided instructions when installing this product. Failure to do so could place the vehicle
occupants in a potentially dangerous situation. After installing or reinstalling, re-check to insure that the product is properly installed.
AMP Research PowerStep running boards automatically move
when the doors are opened to assist entering and exiting the vehicle.