AMP Research PowerStep 76136-01A User manual

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INSTALLATION GUIDE
AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday - Friday, 7:00 AM - 5:00 PM PST
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.
APPLICATION LENGTH MODEL YR PART #
Ford Ranger - Super Crew 72” 2019 76136-01A
Ford Ranger - Super Cab 65” 2019 76136-01A
INSTALLATION TIME
TOOLS REQUIRED
qSafety goggles
qMeasuring tape
q10 mm socket
q10 mm ratchet wrench
q13 mm ratchet wrench
q15 mm ratchet wrench
qRatchet wrench and extension
qPliers
qWire crimpers
qWire stripper / cutter
q3/16” H ex key wrench (allen wrench)
qElectrical tape
qWeather proof caulking (silicone sealer)
q1/8” Drill bit
q9/32” Drill bit
qDrill
qHeat Gun
SKILL LEVEL
4= Experienced
12 3 4

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AMP RESEARCH POWERSTEPTM – FORD RANGER
EXPLODED VIEW
• Motor
• Socket cap screw
• Motor Linkage assembly
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.
INSTALLATION GUIDE
Attaching motor to Linkage assembly
The motors must be attached to the Linkage assemblies on step 5

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AMP RESEARCH POWERSTEPTM – FORD RANGER
2x2
Idler Linkage Assembly (Front)
COMPONENT/PARTS IDENTIFICATION
3x2
Motor Linkage Assembly (Rear)
(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
Note: Some Applications require modication.
Application Cut Length
Crew Cab 72” (No Modication Required)
Extended Cab 65” (Trim 7”)

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AMP RESEARCH POWERSTEPTM – FORD RANGER
7x2
Motor
8x2
Motor Cover
9x4
LED Lamp
x 8
Hex Flange Bolt
4
Wire Harness
11
x8 13
x2
Socket Cap Screw
10
5
Controller STA
Posi-Lock Connector
12
Posi Lock
x2
6
ODB II Plug

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AMP RESEARCH POWERSTEPTM – FORD RANGER
14 x6
Cinch Fastener 15 16
Cable Tie 7”
x20
18
Cable Tie 11”
x2
Butt Connector
Grommet
19 x8
x4
x5
17
M8 Head Hex Bolt

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AMP RESEARCH POWERSTEPTM – FORD RANGER
2
1
Locate Front Idler linkage location. If plastic
plugs are present remove plastic plugs to
expose threads.
Pre thread supplied M10 ange bolt and hook
linkage over bolt as shown. Once linkage is in
position thread in rear linkage mounting bolt.
Snug up bolts but do not torque.
Locate Rear Drive linkage location. If plastic plugs are present remove plastic plugs to expose
threads.
Pre thread supplied M10 ange bolt and hook linkage over bolt as shown. Once linkage is in
position thread in rear linkage mounting bolt. Snug up bolts but do not torque.
3

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5
1
1
23456 7 8
Install board to linkages. Measure approx. 4.5”
from back of linkage to the tip of the board as
shown. Tighten socket cap screws (10) with
3/16” Allen wrench. Torque to 10ft-lbs. Hand
cycle the board to ensure no bind is present.
Once veried Torque linkage mounting bolts
(13) from steps 1-4 to 30ft-lbs.
Install motor onto linkages using supplied
Hex head bolts (18). Torque to 36in-lbs. (See
page 2 for motor install)
Remove Fuse from powerstep wire harness. Mount controller using
supplied zip ties to harness in front of battery as shown. Connect
positive leads from harness. Red to positive battery terminal and black
to negative battery terminal.
6
Remove fuse.
4

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7
Route the two wire harness legs down over to each
wheel well. Long leg will run across to passenger
side, short leg will run down to driver side.
Ensure loom is free from steering and exhaust
components.
Remove oor mat and sill plate cover to
expose oor below.
Locate hole forward of rubber plug. Approx location is in footwell area of cab. Use a 9/32” drill bit
and drill thru oor. While drilling lift carpet to ensure drill bit does not damage carpet inside cab.
Insert provided grommet (17) and trigger wires thru hole. Route wires towards kick panel area.
8
9

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AMP RESEARCH POWERSTEPTM – FORD RANGER
11
Locate OBD port and remove bolt and nut holding it in place with 8mm socket to gain better
access to back side of plug.
Factory Can Wire OBD Module wire Color
Grey with Orange Stripe White Wire
Purple with Orange Stripe Blue Wire
Locate the following wires and connect with supplied posi taps to the following wire colors listed
below.
10

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13
14
Use supplied posi lock connectors to attach
the 2 purple wires of the obd harness to the
main harness. Attach matching colors on the
harness to the wires on the module. Lastly
reinstall Factory OBD port removed in step 11.
Plug in module to OBD port on the vehicle.
Reinstall sill plate removed from step 8.
Vehicle Port
Powerstep
Connection Module
Direct to Port Option
Powerstep
Control Module
To Vehicle
Power (12V)
To Powerstep
Motors
Powerstep
Control Module
To Vehicle
Power (12V)
To Powerstep
Motors
Powerstep
Connection Module
Vehicle Port
Pass-Through Harness Option
Vehicle Port
Pass-Through Harness
(pin-topin at each terminal)
New Vehicle Port
(replaces original port)
Plugs into vehicle
under dashboard
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 to
OBD II port on the vehicle. Secure harness with supplied tie wraps. Note: If the OBD II pass thru
harness (76404-01A) was purchased see install sheet supplied in packaging. The pass through harness
allows for an open port for other accessories. See below for a brief description.