AMP Research PowerStep User manual

www.amp-research.com 1/13 IM77104 rev 07.02.15
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 #
Ford Super Duty - Crew Cab 1999-2001 2004-2007 77104-01A
5-Year Limited Warranty
WARRANTY
Note:The application works only on the Crew Cab model Vehicles.

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AMP RESEARCH POWERSTEPT M – FORD SuperDuty
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
80-03129-90 Motor
19-03179-90 Socket cap screw
19-03133-90 Washer
19-03138-90 Drive Gear Housing Cover

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AMP RESEARCH POWERSTEPT M – FORD SuperDuty
1x2
Running board assembly
D
B
(A) End cap left (x1)
(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
5
Wire harness
3
Idler Linkage assembly
x2 x2
6
A06 Controller
7
Posi-Tap™
x4 8x18
M8 Hex Bolt w
Conical washer
4
Rail Assembly
9x10
M10 Button Head
bolt
x2

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AMP RESEARCH POWERSTEPT M – FORD SuperDuty
Socket Cap Screw
16 x8
Cable tie (11”)
22 x2
Cable tie (7”)
20
x20
23
LED Lamp
x4
15 x6
5/16 Flange Bolt
13
M5 Washer
x6
12 x6
M5 Hex Bolt
24
Butt Connector
x10
14 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
M10 washer
10 x10
Flange Nut
11 x10
21 x10
M8 U-nut

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AMP RESEARCH POWERSTEPT M – FORD SuperDuty
28 x2
Gear Cover 29 x2
Motor
32
Double-diode
x2
(Not required for all applications
See Wiring Guides for details)
31
Tubing
(installation tool)
30 x2
Connecting wire (red)

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AMP RESEARCH POWERSTEPT M – FORD SuperDuty
Insert and position Carriage bolts (17) into slot on rail (4). Insert from either end of rail. Using Flange Nuts
(18) provided assemble Brackets 2x (27) & 1x (28) onto the rail (4). Next install Flange Bolt (15) and Flange
Nut (18) onto bracket tab. Driver side shown. Dimensions shown are for reference. Do not tighten this will
allow for rail adjustment when mounted onto vehicle.
Set rail up into position. Starting with the rear bracket work towards the two front brackets. Insert U nuts
(21) into position. Use provided button head bolts (9) with washers (10) and Flange Nut (11) on lower set of
mount holes and captive washer bolt(8) on upper set of holes of brackets. Snug to body
Thread supplied bolts 2x (8) into Front Drive Linkage.
Repeat step for Rear Idler Linkage. Do not tighten.
8
Note: Badge on rail sits towards the rear of the vehicle!
13
16
DRIVING ASSEMBLY
IDLER
ASSEMBLY
FRONT
Driver Side
8.50
44.00
74.00
Install provided spacer (17) and M6 bolt (12) into
upper mount as shown on both the Drive and Idler
linkages. Do not tighten.
8
14
19
1
2
3 4

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AMP RESEARCH POWERSTEPT M – FORD SuperDuty
Torque bolts on mounting brackets as shown to 16ft-
lbs.
18
15
Slide mounting T-nut into position, Center board in
rail pocket. Tighten fasteners to 10 ft-lbs.
Using a 13mm socket Torque linkage bolts 4x (8) from
step 3 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.
Attach motor to harness. Using a 4mm hex Torque
to 36 in-Lbs.
8
14
19
Start from rear of vehicle tighten brackets to the body of the vehicle. First Torque Button Head Bolts(10) to
16ft-lbs and then tighten Captive washer bolts(8) to 16 ft-lbs.
56
7
89

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AMP RESEARCH POWERSTEPT M – FORD SuperDuty
4
5
4
+
_
6
20
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.
5
5
6
5
4
14
14
Puncture grommet and
thread trigger wire
Open passenger door
Remove step plate
11
1
12
5
13
10
5
14

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AMP RESEARCH POWERSTEPT M – FORD SuperDuty
Remove kick plate
Roll back carpet
See Detail 14
6
wire bundle
TRIGGER WIRE
(See Wiring Guides for wiring details)
Roll back carpet and pull trigger-wire through
grommet.
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
procedures will vary per model year)
Rear Door Ajar Wire
NOTE: Steps 18-27, removing driver’s door panel, only for vehicles prior to 2007.
17
1
5
18
15
5
5
16

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AMP RESEARCH POWERSTEPT M – FORD SuperDuty
18
(See wiring guides and step-by-step instrctions;
colors and precedures will vary per model year)
Connecting Wire
Door Ajar Wire
15
Insert plastic tube
Remove door light
Remove speaker screws
(See Step 22)
Pull back door lining
21
1
5
23
19
5
24
5
20
5
22