Bestop powerboard nx User manual

INSTALLATION TIME SKILL LEVEL
3 Hours 3 - Moderately Difficult
TOOLS
Vehicle Application
•Dodge Ram 1500 Crew Cab
2009 - Current
Part Number: 75638-15
10mm, 13mm
and 19mm
5mm
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Installation Instructions
Automatic Retracting Running Board
PowerBoard®NX
•Dodge Ram 1500 Quad Cab
2009 - Current
Part Number: 75643-15
10mm and
13mm
•Dodge Ram 2500/3500 Mega Cab
2010 - Current
Part Number: 75638-15
Patent Pending

PowerBoard®NX – Installation Instructions
Rev. G 0713 75638 / 75643 pg. 2
Motor Linkage,
Right (Shown) -
Part Number
475.54, Qty - 1
Left - Part
Number 475.55,
Qty - 1
7" Cable Ties, Part Number 460.99, Qty - 25
11" Cable Ties, Part Number 470.02, Qty - 2
Running Board Assembly, Qty - 2
72" - Part Number 473.14
79" - Part Number 460.87
Left End Cap,
Part Number
460.83, Qty - 1
Right End Cap,
Part Number
460.82, Qty - 1
T-Nut Insert, Part
Number 460.84,
Qty - 2 M6 Nut Plate,
Part Number
460.86, Qty - 2
M6-1.0 x 10mm Socket
Cap Screw, Part Number
460.85, Qty - 2
Light, Part Number
470.15, Qty - 4
M8-1.25 x 30 Hex
Bolt, Part Number
473.18, Qty - 12
Reinforcement Bracket,
Part Number 494.62,
Qty - 4
M6-1.0 x 20 Socket Cap Screw,
Part Number 470.00, Qty - 8
8mm Washer,
Part Number
470.07, Qty - 1
8 mm Washer,
Part Number
470.05, Qty - 8
M8-1.25 x 25
Hex Bolt, Part
Number 460.46,
Qty - 1
M8-1.25 Nylock
Nut, Part Number
470.06, Qty - 1
Brake Cable
Bracket, Part
Number 473.78,
Qty - 1
Parts List and Hardware Identification
75643 Quad Cab Only
M8-1.25 Rivet Nut, Part
Number 473.75, Qty - 8
Rivet Nut Tool, Part
Number 473.76, Qty - 1
M6-1.0 x 35 Socket Cap
Screw, Part Number
460.95, Qty - 6
M6-1.0 x 30 Hex Bolt,
Part Number 474.36,
Qty - 4
8 mm Fender
Washer, Part
Number 470.07,
Qty - 4
M8-1.25 x 15 Flange
Bolt, Part Number
473.81, Qty - 2
Front Support Bracket - Rt,
Part Number 481.86, Qty - 1
Bracket Insert,
Part Number
473.35, Qty - 4
Roll Pin, Part
Number 475.12,
Qty - 8
Idler Linkage,
Right (Shown) -
Part Number
475.52, Qty - 1
Left - Part
Number 475.53,
Qty - 1
Rear Support
Bracket, Part
Number 474.35,
Qty - 2
Not used on Mega
Cab
Front Support Bracket - Lt,
Part Number 481.87, Qty - 1
M6-1.0 x 15 Socket Cap Screw,
Part Number 481.93, Qty - 2
Mounting Insert, Part
Number 474.34,
Qty - 4
Blind Rivet, Part Number
474.80, Qty - 4
Wiring Harness, Part
Number 495.56, Qty - 1
M6 Flat Washer,
Part Number
481.96, Qty - 8
Blue Controller, Part
Number 496.11, Qty - 1
Motor (for use with Blue
Controller), Part Number
496.12, Qty - 2
Magnet, Part
Number 491.97,
Qty - 5 Magnet Holder, Part
Number 491.98, Qty - 5
Sensor - Passenger
Side Front, Part Number
492.00, Qty - 1
Wireless Component Kit
Sensor - Passenger
Side Rear, Part Number
492.02, Qty - 1
Sensor - Driver Side
Front, Part Number
492.01, Qty - 1
Sensor - Driver Side
Rear, Part Number
492.03 , Qty - 1
Receiver, Part Number
491.99, Qty - 1
17" Nylon Zip Tie, Part
Number 492.06, Qty - 2

PowerBoard®NX – Installation Instructions
Rev. G 0713 75638 / 75643 pg. 3
RF System Overview System Initialization
The PowerBoards®are activated by Sensors that
are to be mounted inside the door openings for
each door. The Sensors are off when a magnet is
next to the Sensor end that has the two screws.
The Sensor triggers the PowerBoards®to deploy
when the magnet is moved about 3 inches away
from the Sensor. The magnet can work in either of
the locations shown to signal the PowerBoards®to
retract.
Be sure to mount the Sensors in a location that will
allow removal of the screws for battery replacement.
See Battery Replacement at the end of the
instructions.
See Steps 31 – 37 for detailed instructions.
Sensor
Sensor
Screws
Magnet
Magnet
Magnet
Holder
Magnet
Holder
Deployed
Retracted
a. Remove fuse from the PowerBoard®wire harness
and connect the red lead to the battery positive
and the black lead to negative.
b. Layout the harness so the long leg crosses the
engine compartment towards the drivers side and
the short leg is on the passenger side.
c. Attach a motor to each motor link with 3 M6-1.0 x
35mm Socket Cap Screws.
d. Plug the Controller, Receiver, Motors and Lights
into the harness.
e. Plug the fuse back into the harness. After a one
second delay the linkages will retract as shown.
f. Lay out all four sensors as they would be installed
on the vehicle with the drivers side to your left and
the passengers side to your right. Place a magnet
next to each sensor as shown in the overview
above.
g. Move the magnet more than 4 inches away from
the driver front sensor. All four lights will come on
and the drivers side linkage will deploy.
h. Move the magnet back to the sensor and after a
three second delay the lights will turn off and the
linkage will retract.
i. Repeat with the remaining sensors and the lights
and corresponding linkage will operate in the
same manner.
j. Remove the motors to continue with the
installation.
If the system does not operate as stated above
see the Troubleshooting and Battery Replacement
sections at the end of the instructions or go to our
web site at http://www.bestop.com/support.
Front Door
(Alternate)
Rear Door
(Alternate)
Receiver
Front / Rear
Door (Primary)

PowerBoard®NX – Installation Instructions
Rev. G 0713 75638 / 75643 pg. 4
Locate the brake cable adjustment nut on the driver’s
side of the frame toward the rear. Mark the position
of the nut. Hold the adjustment nut with a 13mm
wrench and loosen the cable to create some slack.
Install Brake Cable Bracket -
Quad Cab Only
Steps 2 through 5 are for Quad Cab
Vehicles only. If you have Crew Cab,
skip to Step 6.
Install Brake Cable Bracket -
Quad Cab Only Install Brake Cable Bracket - Quad Cab Only
Once you have enough slack, detach the brake
cable just behind the brake cable adjustment nut. Depress the locking tabs on the brake cable guide and slide it out through the hole in the frame.
Unthread the brake cable from the frame mount.
Slide the brake cable guide into the Brake Cable
Bracket provided in the parts kit. Use the Hex Bolt,
8mm Washer and Nylock Nut from the kit to mount
the Brake Cable Bracket to the frame.
Reattach the brake cable and adjust the brake cable
adjustment nut to its original position.
Install Brake Cable Bracket -
Quad Cab Only
Brake Cable
Bracket
Hex
Bolt
8mm
Washer
Nylock
Nut
Locate the mounting points for the Idler and Motor
Linkages. The Motor Linkage mounts in the front
and the Idler Linkage mounts in the rear. Remove
the tape from the sill drain hole at both mounting
points.
Set a Reinforcement Plate in place and position
with the Rivet Nuts. Use the bracket as a template
to drill a 1/8" hole.
Locate Linkage Mounting
Points Install Reinforcement Bracket
Passenger side shown
Front Mounting Point
Rear
Mounting
Point
Reinforcement
Bracket

PowerBoard®NX – Installation Instructions
Rev. G 0713 75638 / 75643 pg. 5
Vehicles except Quad Cab: Tap a
Roll Pin in the small upper hole in the
Linkage. Hold the Linkage firmly and
use an M6 x 30 Hex Bolt to install the
Mounting Insert in the center hole in
the Linkage. Make sure the insert is
oriented properly
Quad Cab Idler Linkages Only:
Install the Mounting Insert in the rear
hole and tap a Roll Pin in the small
lower hole.
All other applications: Tap a Roll Pin
in both small holes.
Once the Rivet Nuts are in place, use a screwdriver to push the tab on the
Reinforcement Bracket back into the hole to avoid interference with the Linkage
Mount.
Install M8-1.25 x 30 Hex Bolts and Washers in the Rivet Nuts. Leave about 1/2”
of thread showing. Make sure that the M8 Washers are flush to the bolt head.
Orient Mounting Insert on LinkageSecure Reinforcement Bracket
Rivet Nuts
M8 Washers
M8-1.25 x 30
Hex Bolts
Mounting
Insert
Pin
M6 x 30
Hex Bolt
Assemble a Hex Bolt, Rivet Nut Tool and Rivet Nut.
Place the assembly into the cutout in the sill. Hold
the Rivet Nut Tool with a 19 mm wrench and tighten
the bolt until the Rivet Nut deforms and secures to
the sheet metal (15 ft. lbs.). Hold the Rivet Nut Tool
with a wrench and remove the bolt and tool. Repeat
for all Rivet Nuts in the four linkage mounting
positions.
Install Rivet Nuts
Hex
Bolt
Rivet
Nut
Rivet Nut
Tool
Once the hole is drilled, insert a piece of string or
wire through the hole in the Reinforcement Bracket.
Set the bracket into position.
Set the Rivet Nuts into place for alignment. Make
sure the Reinforcement Bracket is flush to the body
of the vehicle. Insert the Blind Rivet through the
hole in the Reinforcement Bracket and secure in
place. When the rivet is installed, remove the string
or wire from the bracket.
Install Reinforcement Bracket Install Blind Rivet
Make sure the Reinforcement Bracket is
flush with the body before securing Blind
Rivet.
Install Blind
Rivet
Reinforcement
Bracket
String or
Wire

PowerBoard®NX – Installation Instructions
Rev. G 0713 75638 / 75643 pg. 6
Orient the Linkages on the vehicle with the Idler Linkages to the rear and the
Motor Linkages to the front. The feet on the Linkages should face each other
on each side of the vehicle.
Orient Linkages
Retract the Linkage part way and make sure the Mounting Insert is in the
proper position. Tilt the Linkage and slide the mounting slots over the bolts
installed in Step 7. Rotate the Linkage until the Mounting Insert slips into the
slot in the sheet metal.
Install Linkages
M8-1.25 x 30
Hex Bolt
Slip
Mounting
Insert into
slot
Use a 10mm wrench to tighten the M6 Flange Hex Bolt
to 12 ft. lbs. Do not allow the bolt to rotate counter-
clockwise which may disengage the Mounting Insert.
Then tighten the lower Hex Bolts to 16 ft. lbs.
Repeat for all Linkages
Install Linkages
Tighten to
12 ft. lbs.
Tighten to
16 ft. lbs.
Driver’s Side Shown
Driver’s Side
Front Shown
Driver’s Side
Front Shown
Slide a Bracket Insert into the access hole in the body support member above the front Motor Link.
Push it forward and over to the hole next to the body mount. Thread an M8-1.25 x 30 Hex Bolt with
a Large Washer into the insert. Hook the Front Support Bracket over the Large Washer and attach
it to the top front boss on the Motor Linkage with an M6-1.0 x 15mm Socket Screw and M6 Flat
Washer. The M6 screw will go in the outboard slot on the left side and the inboard slot on the right.
Tighten all fasteners and repeat on other side.
Install Front Support Bracket
Driver’s Side Shown
Bracket
Insert
Front Support
Bracket
M8-1.25 x 30
Hex Bolt with
Large Washer
Motor
Linkage
M6-1.0 x 15mm
Socket Screw and M6
Flat Washer

PowerBoard®NX – Installation Instructions
Rev. G 0713 75638 / 75643 pg. 7
Loosely wrap 11" Cable Ties around the large bundle
of wires behind the battery in engine compartment.
Slide the Controller through the Cable Ties and
tighten.
Install Controller
11" Cable
Ties
Controller
Install Bracket Insert
Thread an M8-1.25 x 30 Hex Bolt and Large Washer
into a Bracket Insert. Slide the Bracket Insert assembly
into the body support member above the Idler Linkage.
Orient the Bracket Insert with the long end pointing
toward the center of the vehicle. Leave enough
threads showing to install the Support Bracket.
Bracket
Insert
Bracket
Insert M8-1.25 x
30 Hex Bolt
Large
Washer
Slide the slotted end
of the Support Bracket
over the M8-1.25
x 30 Hex Bolt and
Large Washer from
the Bracket Insert
Assembly. The lower
part of the bracket
should rest against the
rear of the Idler Linkage.
Install Support Bracket
Align the lower hole in the
Support Bracket with the
threaded hole in the Idler
Linkage. Loosely tighten
the M8-1.25 x 30 Hex Bolt.
Then insert an M8 Flange
Bolt. Check that the
Support Bracket is square
with the Linkage and the
vehicle. Tighten the Hex
Bolt and the Flange Bolt to
16 ft. lbs.
Secure Support Bracket
Idler
Linkage
Support
Bracket
M8 Flange
Bolt
M8-1.25 x 30
Hex Bolt
Idler
Linkage
The Support Bracket is not used on Mega
Cab vehicles. Skip to Step 19.
Removethefuse fromthe
Wiring Harness.
Remove the fuse from the Wiring Harness. Failure
to do so could result in severe electrical shock which
could harm the installer and/or damage the vehicle.
Remove Fuse from
Wiring Harness
Ground
Attach the Wiring Harness to the Controller.
Connect the red power lead to the positive battery
terminal and black lead to the body ground.
Skip to next step if still attached from Step 1.
Attach Power Leads
Ground
Positive
Terminal

PowerBoard®NX – Installation Instructions
Rev. G 0713 75638 / 75643 pg. 8
Route the long leg of the Wire Harness across the
engine compartment to the passenger side wheel
well. Route the short leg to the driver’s side. Secure
them with 7" Cable Ties.
Route Wiring Harness
Wire
Harness
On the driver’s side route the Wire Harness down
along the underside of the floor and the frame.
Secure it with 7" Cable Ties.
Route Wiring Harness –
Driver’s Side
Wire
Harness
Continue to route the Wire Harness along the inside
and top of the driver’s side frame. Secure it with 7"
Cable Ties.
Route Wiring Harness –
Driver’s Side
Wire
Harness
7" Cable
Tie
7" Cable
Tie
Route the Wire Harness down to the wheel well on the Passenger side and along
the top of the frame rail. Secure it with 7" Cable Ties.
You may have to combine Cable Ties to create longer ties.
Route Wiring Harness – Passenger’s Side
7" Cable
Ties
Wire
Harness
Install Receiver
Route the small diameter wire harness along the side of the frame. Find a
location that is protected but is not surrounded by dense metal. Plug in the
Receiver and insert 17" Nylon Zip Ties through the loops on the Receiver.
Mount the Receiver with the stand off ribs against the vehicle.
Due to vehicle variations, installation may differ from
that shown.
Receiver Small Diameter
Wire Harness
Frame
17" Nylon
Zip Ties
Do Not install on or near
hot surfaces.

PowerBoard®NX – Installation Instructions
Rev. G 0713 75638 / 75643 pg. 9
Install Motor
Mount the Steps to the linkages. Slide the mounting T-Nut
into position. Install M6-1.0 x Socket Head Bolts to secure
the boards. Use a 5mm Allen Wrench to tighten the bolts.
Make sure the board moves up and down freely by hand.
If it binds, loosen the linkage to body attachment bolts and
adjust the linkage position until the boards move freely. Do
not tighten the bolts at this time.
M6-1.0 x 20mm
Socket Head Bolts Arm
PowerBoard
Install Running Boards
M6-1.0 x 20mm
Socket Head Bolts
M6-1.0 x 20mm
Socket Head Bolts
Tightening the
fasteners before
cycling the step several times
may create a bind, causing a
squeaking sound and preventing
the boards from retracting
completely and evenly.
Open the back door on the driver’s
side and clean the area where the
magnet and sensor will be installed
with a 50/50 solution of water and
alcohol. Stick a magnet to the back
side of the front door as shown.
Hold the Drivers Front Sensor
against the door pillar and position
the magnet so it is directly in front
of the sensor.
Slide Motor assembly onto drive shaft and mounting
bosses of Motor Linkage assembly. Use three (3)
M6-1.0 x 35mm Socket Cap Screws and M6 Flat
Washers to secure Motor. Plug female connector into
Motor. M6-1.0 x 35mm Socket Cap
Screws and M6 Flat Washers
Driver’s Side
Rear Door
Top Hinge
Magnet
Install Magnet
Torque
5-7 ft. lbs.
(6.78-9.49 Nm /
60-84 in. lbs.)
Do not exceed 7
ft. lbs. of torque
Install Driver’s Side
Front Sensor
Peel the liner off of the Drivers Side
Front Sensor. Position it on the door
pillar so it is about 1/6" away from the
magnet. Press firmly on the Sensor to
stick it to the pillar.
Driver’s Side
Rear Door Driver’s Front
Sensor
Sensor sits
on top of
hinge
Top Hinge
Magnet

PowerBoard®NX – Installation Instructions
Rev. G 0713 75638 / 75643 pg. 10
Install Passenger Side
Sensors and Magnets
Repeat Steps 30 through 33 on the passenger side
of the vehicle.
Install Driver’s Side
Rear Sensor
Peel the liner off of the Drivers Side Rear
Sensor. Position it on the door pillar so
it is about 1/6" away from the magnet.
Press firmly on the Sensor to stick it to
the pillar.
Reinstall Fuse
Driver’s Front
Sensor
Magnet
Driver’s Side
Rear Door
Top Hinge
Driver’s Rear
Sensor
Install Magnet
Open the front driver’s side door and
clean the area where the magnet and
sensor will be installed with a 50/50
solution of water and alcohol. Stick a
magnet to the front side of the rear door
as shown. Hold the Drivers Rear Sensor
against the door pillar and position the
magnet so it is directly in front of the
sensor.
Driver’s Front
Sensor
Magnet
Driver’s Side
Rear Door
Top Hinge
Reinstall fuse in PowerBoard®wire harness.