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.

www.amp-research.com 2/13 IM77104 rev 07.02.15
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

www.amp-research.com 3/13 IM77104 rev 07.02.15
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

www.amp-research.com 4/13 IM77104 rev 07.02.15
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

www.amp-research.com 5/13 IM77104 rev 07.02.15
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)

www.amp-research.com 6/13 IM77104 rev 07.02.15
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

www.amp-research.com 7/13 IM77104 rev 07.02.15
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

www.amp-research.com 8/13 IM77104 rev 07.02.15
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

www.amp-research.com 9/13 IM77104 rev 07.02.15
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

www.amp-research.com 10/13 IM77104 rev 07.02.15
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

www.amp-research.com 11/13 IM77104 rev 07.02.15
AMP RESEARCH POWERSTEPT M – FORD SuperDuty
15
CONNECTING WIRE
15
To rear door wire splicing
CONNECTING
WIRE
T
hread 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
Connect harness to motor. Secure harness with tie
wraps. Affix LED lamp (20) to LED Bracket (22) as shown..
26
1
27
5
25
1
28 1
29

www.amp-research.com 12/13 IM77104 rev 07.02.15
AMP RESEARCH POWERSTEPT M – FORD SuperDuty
Using supplied butt connectors, 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.
Affix LED light bracket assembly to rail. Mount front light rearward of front linkage and mount rear light just
forward of rear linkage.
5
1
31
30

www.amp-research.com 13/13 IM77104 rev 07.02.15
-
AMP RESEARCH POWERSTEPT M – FORD SuperDuty
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
32

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 trapped in 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.

Designed and manufactured by AMP Research. Patent 6,830,257 / 6,641,158 / 6,834,875 / 6,938,909 / 6,942,233 / 7,007,961 Other US and worldwide
patents pending.. 5-year limited warranty. Professional installation is recommended.
TECH SUPPORT 1-888-983-2204 (press 2) Monday - Friday, 6:00 AM - 5:00 PM PST
WIRING GUIDE / General instructions
Posi-Tap™ installation instructions
1. Insert 2. Tighten 3. Strip 3/8”
4. Insert & Tighten
For two or more wires
twist.
Posi-Tap™ Patents: 5,228,875;
5,695,369; 5,868,589, 2,708.
Other patents pending.
Diodes
CAUTION
Handle the motor and linkage assemblies with care when installing. Dropping can damage
motor. Remove fuse from wiring harness during installation. Failure to do so could result in
severe electrical shock.
www.amp-research.com 1/11 IM75104 rev 11.22.10
WIRING GUIDE
NOTE: 2004-2006 Ford Super Duty trucks without remote keyless plus 2001 and older Super Duty trucks
with remote keyless entry require additional diodes that are not included in the standard parts kit.
See specific model year Wiring Guides for quantities required for your application
If needed, additional diodes (Part # Single 19-02727-90 / Double 19-02890-90) may be ordered at no
charge and shipped UPS Ground by calling 1-888-983-2204
.

WIRING GUIDE
Ford Super Duty (2007)
With remote keyless entry
07
W
Passenger-side
wiring
Driver-side wiring
1. Remove front kick panel and locate bundle of wires leaving front door just
above e-brake assembly (Area-A). Open bundle and locate 18Ga door-ajar wire
(yellow with black stripe).
Caution: You may fi nd two wires with these colors; the correct wire will
ground when the door is open (ohm meter will read low resistance with
door open and OL (open line) with the door closed.
2. Using supplied Posi-Tap connectors, splice supplied red connecting wire into
yellow with black stripe wire.
3. Route red wire down to sill plate.
4. Attach purple Power step trigger wire to blue butt connec-
tor of “double diode harness”.
5. Attach one leg of “double diode harness” to open end of
red connecting wire.
6. Using supplied Posi-Tap connectors, splice remaining leg
of “double diode harness” into rear door-ajar wire ( light green
with yellow stripe) Caution: You may fi nd two wires with
these colors; the correct wire will ground when the door
is open (ohm meter will read low resistance with door
open and OL (open line) with the door closed.
1. Remove sill plate and attach purple Power Step trigger wire to blue
butt connector of “double diode harness”.
2. Open wire bundle and locate door-ajar wires ( rear: pink with light
blue stripe; front: grey with red stripe. Both wires pass under front seat
as shown in fi gure-C
3. Using supplied Posi-Tap connectors, splice the open legs of the
“double diode harness” into the door-ajar wires.
4. If necessary, attach red connecting wire to “double diode harness” to
extend length as needed.
www.amp-research.com 2/11 IM75104 rev 8.22.07
AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION

WIRING GUIDE
Ford Super Duty (2007)
With remote keyless entry
07
W
Passenger-side
wiring
Driver-side wiring
1. Remove front kick panel and locate bundle of wires leaving front door just
above e-brake assembly (Area-A). Open bundle and locate 18Ga door-ajar wire
(yellow with black stripe).
Caution: You may fi nd two wires with these colors; the correct wire will
ground when the door is open (ohm meter will read low resistance with
door open and OL (open line) with the door closed.
2. Using supplied Posi-Tap connectors, splice supplied red connecting wire into
yellow with black stripe wire.
3. Route red wire down to sill plate.
4. Attach purple Power step trigger wire to blue butt connec-
tor of “double diode harness”.
5. Attach one leg of “double diode harness” to open end of
red connecting wire.
6. Using supplied Posi-Tap connectors, splice remaining leg
of “double diode harness” into rear door-ajar wire ( light green
with yellow stripe) Caution: You may fi nd two wires with
these colors; the correct wire will ground when the door
is open (ohm meter will read low resistance with door
open and OL (open line) with the door closed.
1. Remove sill plate and attach purple Power Step trigger wire to blue
butt connector of “double diode harness”.
2. Open wire bundle and locate door-ajar wires ( rear: pink with light
blue stripe; front: grey with red stripe. Both wires pass under front seat
as shown in fi gure-C
3. Using supplied Posi-Tap connectors, splice the open legs of the
“double diode harness” into the door-ajar wires.
4. If necessary, attach red connecting wire to “double diode harness” to
extend length as needed.
www.amp-research.com 2/11 IM75104 rev 8.22.07
AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION
WIRING GUIDE
Ford Super Duty (2004 - 2006)
With remote keyless entry
04 - 06
W
Passenger-side
wiring
Driver-side wiring
CAUTION: You will fi nd two wires with these colors; the correct wire will
ground when the door is open (ohm meter will read low resistance with door
open and OL with door closed).
www.amp-research.com 3/11 IM75104 rev 08.22.07
AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION

WIRING GUIDE
Ford Super Duty (2004 - 2006)
Without remote keyless entry
04 - 06
W/O
Driver-side wiring
Passenger-side wiring
SINGLE DIODES REQUIRED
If diodes were not ordered with kit, they can be
ordered at no charge and shipped UPS Ground
by calling 1-888-983-2206
www.amp-research.com 4/11 IM75104 rev 08.22.07
AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION

WIRING GUIDE
Ford Super Duty (2002 - 2003)
With remote keyless entry
02 - 03
W
NOTE: The two wires to
each of the motor plugs
(orange and white) must
be reversed.
Driver-side wiring
Passenger-side
wiring
DRIVER SIDE WIRING
1. Remove front door panel and locate bundle of wires below
and to the left of speaker (Area-A). Open bundle and locate 18
Ga door-ajar wire (yellow with black stripe).
CAUTION: You may fi nd two wires with these colors; use wire
that leads out to door latch.
2. Using supplied Posi-Tap™ connectors, splice supplied red
connecting wire into yellow with black stripe wire.
3. Route red wire back into cab of vehicle and back toward
rear sill plate.
4. Remove rear sill plate, open wire bundle and locate 18 Ga. black wire.
Cut this wire and attach the end of the connecting wire from step-3 as shown
in fi gure-C.
5. Using supplied Posi-Tap™ connectors, splice purple Power Step trigger
wire into rear door-ajar wire (light green with yellow stripe), located under front
sill plate.
CAUTION: You will fi nd two wires with these colors; the correct wire
will ground when the door is open (ohm meter will read low resistance
with door open and OL with door closed).
PASSENGER SIDE WIRING
1. Remove passenger side front sill plate, open wire bundle and locate
rear door-ajar wire (pink with light bllue stripe). This wire will be located
rear of junction where wires route under from passenger seat.
2. Using supplied Posi-Tap™ connectors, splice purple Power Step trig-
ger wire into pink with light blue stripe wire.
3. Cut the black 18 Ga wire found in wire bundle, forward of junction
where wires route under front seat.
4. Using supplied Posi-Tap™ connectors, splice rear section of cut black
wire into fron door-ajar wire (grey with red stripe) as shown above.
5. Tape off the remaining open end of the black wire (front section).
www.amp-research.com 5/11 IM75104 rev 08.22.07
AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION
WIRING GUIDE
Ford Super Duty (2004 - 2006)
Without remote keyless entry
04 - 06
W/O
Driver-side wiring
Passenger-side wiring
SINGLE DIODES REQUIRED
If diodes were not ordered with kit, they can be
ordered at no charge and shipped UPS Ground
by calling 1-888-983-2206
www.amp-research.com 4/11 IM75104 rev 08.22.07
AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION

WIRING GUIDE
Ford Super Duty (2002 - 2003)
Without remote keyless entry
02 - 03
W/O
NOTE: The two wires to
each of the motor plugs
(orange and white) must
be reversed.
Passenger-side
wiring
Driver-side wiring
www.amp-research.com 6/11 IM75104 rev 08.22.07
AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION