AMP Research PowerStep User manual

www.amp-research.com 1/10 IM77105 rev 01.13.20
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, 7:00 AM - 5:00 PM PST
APPLICATION AMP Part #
Ford F150 - SuperCrew 2004-2008 77105-01A
5-Year Limited Warranty
WARRANTY
Note:The application works only on the Super Crew model Vehicles.

www.amp-research.com 2/10 IM77105 rev 01.13.20
AMP RESEARCH POWERSTEPTM – FORD F150
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.
EXPLODED VIEW
• Motor
• Socket cap screw
• Washer
• Drive Gear Housing Cover

www.amp-research.com 3/10 IM77105 rev 01.13.20
AMP RESEARCH POWERSTEPTM – FORD F150
(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
2
Motor Linkage assembly
6
Wire harness
3
Idler Linkage assembly
x2 x2
5
Controller STA
7
Posi-Tap™
x4
8x18
M8 Hex Bolt w
Conical washer
4
Rail Assembly
9x10
M8 Nut w Conical
washer
x2

www.amp-research.com 4/10 IM77105 rev 01.13.20
AMP RESEARCH POWERSTEPTM – FORD F150
Socket Cap Screw
14 x8
Cable tie (11”)
22 x2
Cable tie (7”)
20
x20 23
LED Lamp
x4
13 x6
5/16 Flange Bolt
11
M5 Washer
x6
10 x6
M5 Hex Bolt
24
Butt Connector
x8
12 x4
M6 Flange Bolt
Upper Mount
Spacer
19 x4
25
LED Light
Bracket
x4
5/16-18
Carriage Bolt
17 x10
5/16-18
Flange nut
18 x16
26
Linkage Mounting
Bracket
x4 27
Rail Mounting
Bracket
x2 28 x2
Gear Cover
29 x2
Motor
M8 U-Nut
16 x10
15
M8 Washer
x10
M8 Hex Bolt
21 x10

www.amp-research.com 5/10 IM77105 rev 01.13.20
AMP RESEARCH POWERSTEPTM – FORD F150
Locate mounting points. Frist middle and last set of holes on the inner sill. Install 5 u nuts (16) in upper mount
holes.
Set Brackets into position and use provided M8 Bolts (21) and washers (15) on outside and provided M8
nuts on the backside. Do not tighten.
Using provided captive washer m8 bolts (8) install
upper bracket hardware to brackets. Do not tighten.
15 & 21
15 & 21
Front Linkage
Bracket
Rear Linkage
Bracket
TNORF
Center Rail
Bracket
18
18
8
9
Set Rail up into position. Start with rear bracket work
towards the front brackets. Attach Carriage bolts 5x
(17) and Flange Nut 5X (18). Center rail at front and
rear door line. Torque Flange Nuts to 16 ft-lbs. Insert
Flange bolt (13) and nut (18) into side of bracket. Do
Note: Badge on rail sits towards the rear of vehicle!
8
8
17
13
1
2
3 4

www.amp-research.com 6/10 IM77105 rev 01.13.20
AMP RESEARCH POWERSTEPTM – FORD F150
Using a 13mm socket Torque linkage bolts 4x (8)
from step 5 to 16 ft-lbs Next use a 10mm socket,
torque linkage spacer bolt 2x (12) from step 6 to 8
ft-lbs. Once linkages are tight cycle board to verify
steps deploy under own weight.
Slide mounting T-nut into position, Center board in
rail pocket. Tighten fasteners to 10 ft-lbs.
Attach motor to harness. Using a 4mm hex Torque
to 36 in-Lbs.
8
Install provided spacer (19) and M6 bolt (12) into
upper mount as shown on both the Drive and Idler
linkages. Do not tighten.
Thread supplied bolts 2x (8) into Front Idler Linkage.
Repeat step for Rear Drive Linkage. Do not tighten.
8
Starting from the rear of the vehicle work your way
forward. Using a 13mm socket and wrench tighten
Pinch weld bolts (21) and nut (9) rst to 16ft-lbs.
Next tighten upper sill bolts (8) to 16ft-lbs. Next
torque ange bolt and nut on bracket tab to 16ft-lbs.
8
8
9
9
13
18
8
12 19
56
7
910
8

www.amp-research.com 7/10 IM77105 rev 01.13.20
AMP RESEARCH POWERSTEPTM – FORD F150
5
Remove fan shroud to allow for wire routing. Shroud
will be reinstalled in a later step.
Mount controller with the two 11” tie wraps to
factory conduit. Route wire harness under core
support and down toward controller. Attach
harness to controller (make sure connector locking
tabs fully engage).
Secure harness with tie wraps.
Remove fuse.
Connect red and black
power leads to battery. Red
lead goes to positive.
Route shorter leg of harness
down passenger-side wheel
well.
Route longer leg of harness across front and down
under driver side. Secure harness with tie wraps and
reinstall shroud.
6
Puncture grommet and thread all four trigger wires
up into the cabin of vehicle. The grommet is located
on driver-side behind forward linkage assembly.
Route longer leg of harness down along driver-side
wheel well and along frame of vehicle. Secure with tie
wraps.
6
6
6
6
12
1
13
5
14
15
11
16

www.amp-research.com 8/10 IM77151 rev 01.13.20
AMP RESEARCH POWERSTEPTM – FORD F150
18
Remove drivers-door sill plate and pull back
carpet to reveal trigger wires threaded though
grommet.
Pull wires from grommet and route back along factory
wire harness to back door sill plate.
Locate the appropriate signal wires as noted below.
Note: There may be up to ve Black with Blue Stripe
wires; use the one that looks unique (ie. different
blue stripe... weight and shade).
Remove rear door step plate and open wire bundle.
Route trigger wires to rear door sill plate.
6
6
SuperCrew
6
Black / Yellow
Black / Pink
Black / Blue
Black / White
Driver Front
Pass. Front
Driver Rear
Pass. Rear
21
Using supplied Posi-Taps™, splice Power Step trigger wires into the corresponding door ajar wires. The
SuperCrew (having 4 independent doors) is the only application that will use all four wires; tape off the two
unused trigger wires on the SuperCab and Regular Cab.
7
6
Insert Tighten Strip 3/8” Insert and
Tighten
17
22
19 22
20

www.amp-research.com 9/10 IM77105 rev 01.13.20
AMP RESEARCH POWERSTEPTM – FORD F150
Using supplied butt connectors, connect the lamp
wires. Red to Red, Black to Black. Once Crimped
use heat gun to shrink tube.
Afx LED light bracket assembly to rail. Mount front
light rearward of front linkage and mount rear light just
forward of rear linkage.
Afx LED lamp (23) to LED Bracket (25) as shown..
Connect harness to motor. Secure harness with tie
wraps.
Reinstall Fuse.
Close and wrap conduit with electrical tape. Secure all
loose wires with cable ties. Pull lamp wires upward to
avoid any wire snagging.
18
18
22
25
22
22 22
23
22
24
22
27
22
26

www.amp-research.com 10/10 IM77105 rev 01.13.20
AMP RESEARCH POWERSTEPTM – FORD F150
Check that all doors activate the Power Step and the LED Lights work when doors open and close.
Reinstall any remaining trim panels.
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.
37
27