AMP Research Power Step User manual

www.amp-research.com 1/12 IM75104 rev 09.19.12
INSTALLATION GUIDE
AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday - Friday, 6:00 AM - 5:00 PM PST
APPLICATION LENGTH MODEL YR PART #
Ford Super Duty F-250 / F-350 Regular Cab*(48”) 1999-2001 / 2004-2007 75104-01A
Ford Super Duty F-250 / F-350 Super Cab*(60”) 1999-2001 / 2004-2007 75104-01A
Ford Super Duty F-250 / F-350 Crew Cab (79”) 1999-2001 / 2004-2007 75104-01A
Ford Excursion* (79”) 2000-2001 / 2004–2005 75104-01A
*Modication required to running board assembly. See Item 1 on page 3.
TOOLS REQUIRED
q Safety goggles
q Measuring tape
q Flat blade screwdriver
q Phillips head screwdriver
q 13mm socket
q 8mm 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 9/32” Drill Bit
q 25/64” Drill Bit
q Weather proof caulking ( silicone
sealer )
INSTALLATION TIME
12 3 4
SKILL LEVEL
4= Experienced
3-5 Hours
Professional installation recommended
5-Year Limited Warranty
WARRANTY
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.

www.amp-research.com 2/12 IM75104 rev 09.19.12
AMP RESEARCH POWERSTEPTM – FORD SUPER DUTY & EXCURSION
INSTALLATION GUIDE
Attaching motor to linkage assembly
The motors must be attached to the linkage assemblies before continuing the
installation process.
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
80-03129-90 Motor
19-03179-90 Socket cap screw
19-03133-90 Washer
19-03138-90 Drive Gear Housing Cover

www.amp-research.com 3/12 IM75104 rev 09.19.12
AMP RESEARCH POWERSTEPTM – FORD SUPER DUTY & EXCURSION
Note: Some Applications require modication.
Application Cut Length
Crew Cab/Excursion 79” (No Modication Required)
Super Cab 60” (Trim 19”)
Regular Cab 48” (Trim 31”)
5
2x2
10-02641-14
Idler linkage assembly
3x2
10-02624-14
Motor linkage assembly
4
19-02726-91L
Wire harness
19-03297-AO6
Controller
6
19-02890-90
Double-diode
x2
(Not required for all applications
See Wiring Guides for details)

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AMP RESEARCH POWERSTEPTM – FORD SUPER DUTY & EXCURSION
7x8
19-02487-90
Hex bolt
8x8
19-02485-90
Button head - M10
9x2
19-03339-90
Cable tie (11”)
10 x8
19-02802-90
Socket cap screw
11 x8
19-02488-90
U-nut
12 x8
19-02486-90
Washer (stainless)
13 x8
16-03014-90
Washer (black)
14 x25
19-02805-90
Cable tie (7”)
15
19-02992-90
Tubing
(installation tool)
16 x2
19-02986-90
Connecting wire (red)
17 x10
19-02989-90
Butt connector
PARTS LIST AND
HARDWARE
IDENTIFICATION
18 x4
19-03354-90
Posi-Tap® connector
19 x4
19-03302-90
LED Lamp
20 x4
19-02640-90
Grommet

www.amp-research.com 5/12 IM75104 rev 09.19.12
AMP RESEARCH POWERSTEPTM – FORD SUPER DUTY & EXCURSION
1
2 3
45
DRIVING ASSEMBLY
IDLER
ASSEMBLY
FRONT
Driver Side
7
15
12
814
7
2
2
8
2
TORQUE
16 ft-lbs.
(22 N m)
Note: Excursion requires hole to be drilled in body for
rear linkage. Use 25/64” Drill Bit.

www.amp-research.com 6/12 IM75104 rev 09.19.12
AMP RESEARCH POWERSTEPTM – FORD SUPER DUTY & EXCURSION
6
7 8
9 10
5
9
Loop two large tie wraps through fastener cutouts in sheet metal as shown. Position
controller as shown above and cinch down tie wraps to secure controller in place. Connect
harness to controller. Make sure that locking tabs on controller/harness connector are
fully engaged.
4
4
5
4
+
_
4
4
14
14 14

www.amp-research.com 7/12 IM75104 rev 09.19.12
AMP RESEARCH POWERSTEPTM – FORD SUPER DUTY & EXCURSION
15
13 14
11 12
4
14
14
Puncture grommet and
thread trigger wire
Remove kick plate
Roll back carpet
See Detail 14
6
wire bundle
TRIGGER WIRE
(See Wiring Guides for wiring details)
18
Connecting Wire or leg of Double Diode
TRIGGER
WIRE
6
Roll back carpet
See Detail (See wiring guides for details and
step-by-step instuctions; colors and
proceedures will vary per model year)
Rear Door Adjar Wire
Roll back carpet and pull trigger-wire through
grommet.

www.amp-research.com 8/12 IM75104 rev 09.19.12
AMP RESEARCH POWERSTEPTM – FORD SUPER DUTY & EXCURSION
16 17
18 19
20 21
Remove door light
Remove speaker screws
(See Detail 22)
Pull back door lining
NOTE: Steps 16-25, removing driver’s door panel, only for vehicles prior to 2007.

www.amp-research.com 9/12 IM75104 rev 09.19.12
AMP RESEARCH POWERSTEPTM – FORD SUPER DUTY & EXCURSION
24 25
22 23
26 27
18
(See wiring guides and step-by-step instrctions;
colors and preceedures will vary per model year)
Connecting Wire
Door Ajar Wire
15
Insert plastic tube
15
CONNECTING WIRE
15
To rear wire splicing
CONNECTIN
G
WIRE
Thread wire through tube then remove
tube
6
rear door
ajar wire
TRIGGER WIRE
CONNECTING
WIRE
18
open leg of double
diode harness
rear door ajar

www.amp-research.com 10/12 IM75104 rev 09.19.12
AMP RESEARCH POWERSTEPTM – FORD SUPER DUTY & EXCURSION
28 29
30 31
32 33
28 29
30
32
31
33
#
44
3
4
3
2
2
1
10
27”
65”
On each side of the vehicle measure from the front
edge of door line on the pinch weld to the specied
lengths below. Measure at 27” for front LED Light
and 65” for rear LED LIght.