AMP Research Running Boards Installation Instructions

AMP Research Running Boards Installation Instructions
INSTALLATION GUIDE
APPLICATION
LENGTH
Ford F-250 / F-350 / F-450 Regular Cab * (48”) Ford F-250 / F-350 / F-450 Super Cab * (60”)
Ford F-250 / F-350 / F-450 Crew Cab (79”)
MODEL YR
PART #
2002-2003, 2008 - 2012
2002-2003, 2008 - 2012
2002-2003, 2008 - 2012
75134-01A
75134-01A
75134-01A
*Modification required to running board assembly. See Item 1 on page 3.
INSTALLATION TIME
3-5 Hours
Professional installation recommended
SKILL LEVEL
1
2
3
4= Experienced
4
TOOLS REQUIRED
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Safety goggles
Measuring tape
Flat blade screwdriver
Phillips head screwdriver
13mm socket
8mm socket
Ratchet wrench and extension
Wire crimpers
Wire stripper / cutter
3/16” hex key ( allen wrench )
4mm hex key ( allen wrench )
Electrical tape
Silicone caulking (sealer)
25/64” Drill Bit
9/32” Drill Bit
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
INSTALLATION GUIDE
Attaching motor to linkage assembly
The motors must be attached to the linkage assemblies before continuing the
installation process.
Exploded View
80-03129-90 Motor
19-03179-90 Socket cap screw
19-03133-90 Washer
19-03138-90 Drive Gear Housing Cover
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.
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
Note: Some Applications require modification.
Application
Crew Cab
Super Cab
Regular Cab
A
F
Cut D
imen
1
x2
Running board assembly
sion
C
(A) 19-03763-90 End cap left (x1)
(B) 19-03760-90 End cap right (x1)
(C) 19-02663-90 T-nut insert (x2)
(D) 19-02802-90 Socket cap screw (x2)
(E) 19-03761-90 End cap wedge right (x1)
(F) 19-03764-90 End cap wedge left (x1)
3 x2
2 x2
19-03473-92L
Wire harness
E
B
10-02624-14
Motor linkage assembly
10-02641-14
Idler linkage assembly
4
Cut Length
79” (No Modification Required)
60” (Trim 19”)
48” (Trim 31”)
5
19-03297-B05
Type-B Controller
D
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
PARTS LIST AND
HARDWARE
IDENTIFICATION
7
x8
19-02487-90
Hex bolt
12
x8
19-02488-90
U-nut
17
x2
19-03339-90
Cable tie (11”)
21
x4
19-02640-90
Grommet
8
10
9
x8
19-02485-90
Button head - M10
13
19-02389-90
Large OD Washer
11
x8
19-02849-90
Socket cap screw
19-02802-90
Socket cap screw
14
15
x8
19-02486-90
Washer (stainless)
x8
16-03014-90
Washer (black)
16-03048-90
Brake cable bracket
22
x4
19-03302-90
LED Lamp
x25
19-02805-90
Cable tie (7”)
22
16
19-03353-90
Nylock nut
20
18
19
10-00115-60
Nylock nut
x4
19-03354-90
Posi-Tap® connector
x8
19-03911-90
Butt connector
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
Driver
Side
Driver
SideShown
IDLER
ASSEMBLY
Use second and last set of
mounting holes, counting
from the front.
FR
ON
1
T
DRIVING ASSEMBLY
NOTE: Driving Linkage assembly mounts in the front;
idler mounts in the rear. (Superduty and Excursion)
Torque fasteners to 16 ft-lbs. (22 N m).
7
15
7
8
14
2
12
2
Steps 4 & 5 for 2008-Current Model Years Only
Disengage parking brake.
Pull parking brake cable rearward from forward
support bracket to create slack in cable. Secure
cable slack with locking pliers.
4
3
Note: Excursion requires hole to be drilled in body for
rear linkage. Use 25/64” Drill Bit.
Remove cable from rear support bracket and
install cable bracket extension with large washer
on front side of bracket. Re-install parking brake
cable and remove locking pliers.
5
11
13
19
9
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
Secure controller to vehicle wire loom beside
battery (on passenger side) and connect both
Power Step wire harness connectors to connectors
on controller. Secure locking tabs on connectors.
Remove fuse from harness.
4
6
12
7
Connect power and gound for controller to
battery, Red to positive and Black to the
negative lead. Route harness legs down
over wheel wells toward motor linkages,
long leg across front and over to driver side.
Secure all loose sections of the harness with
cable ties.
8
7
Run wire legs down and along underside of vehicle floor, securing with tie wraps. Run trigger wires (4)
on passenger side through grommet as shown bellow.
4
9
Driver-Side
Passenger-Side
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
Roll back carpet and pull trigger-wire through
grommet. Use silicone glue to seal holes in
grommet.
Open passenger door and remove
sill plate and kick panel.
10
11
2008-Current Wiring
Flat Loom
(under carpet)
(for 2002-2003 models skip to step 13)
Note: Some models may
not have a Flat Loom.
White wire can be located
in cloth wrapped loom.
White Wire
11
See detail on next
step for wiring.
Using supplied PosiTaps®, connect trigger wires into
corresponding door ajar wires. The Power Step trigger
wires color coordinate with the factory door ajar wires.
Note the differences explained below for Regular Cab
and Super Cab.
Front Driver-Side Door: Dark Green with Purple stripe
Note: Some later models will have a Light Green with
Purple stripe. Using an Ohm meter the correct wire
will ground when the front door is closed and OL
Trigger Wires
with the front door open.
Rear Driver-Side: Dark Green Note: Some later models will have a Light Green wire. Using an Ohm meter
the correct wire will ground when the rear door is
closed and OL with the rear door open.
13
14
REGULAR CAB/SUPER CAB NOTE: Connect this wire
to front door wire also (Dark Green w/ Purple stripe)
because these models don’t have rear door ajar wires.
Front Passenger-Side: White... found just below flat
loom as shown in the illustration above. Some later
models may not have a Flat Loom. See image for no
Flat Loom models.
Rear Passenger-Side: Yellow... the correct yellow wire
continues on to back door. Pull on the yellow wire that
leads to the back and does not cross over to driver side
at junction; you’ll notice the movement of the correct
wire up where we connect our trigger wires.
15
12
Insert
Tighten
Strip 3/8”
Insert and
Tighten
REGULAR CAB/SUPER CAB NOTE: Connect this wire
to passenger front door wire also (White), because these
models don’t have rear door ajar wires.
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
NOTE: Steps 13-23 are only for model years 2002-2003 with factory remote keyless entry. For all other model years continue to step 24.
2002-2003 model year trucks require that the Green
and Green/Violet wires be routed over to the driver
side of the vehicle. Attach extra wire length to both
wires on the harness (Green and Green/Violet), and
run under carpet from passenger side to driver side.
Open driver side door and remove sill plate and kick
panel. Lift carpet and pull trigger wires to driver side.
28
13
29
Remove driver side front door panel. This will
require removing multiple concealed bolts and
paneling.
30
14
Door panel removal will require removal of door
light lens and window corner trim.
31
15
Remover speaker and pull back door lining.
Insert plastic tubing (for wire routing) and run
one trigger wire through to door compartment.
Then remove the plastic tubing, pulling from
door side.
(See Detail 18)
32
16
Pull back door lining
33
17
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
Driver Front Door Wiring: Using Posi-Tap connector, connect the supplied additional wire (Red)
to front door ajar wire (Yellow w/Black stripe)
Driver Rear Door Wiring: Attach second connecting wire on driver side to rear door ajar wire (Light
Green w/Yellow stripe), found under front door sill
plate.
Driver Door Ajar
(Yellow w/Black)
supplied additional wire
28
18
CAUTION: You will find two wires with these colors;
the correct wire will ground when the rear door is
closed and OL with the rear door open.
CONNECTING
WIRE
29
19
Rear Door Ajar
(Light Green w/Yellow)
Passenger Front Door Wiring: Using Posi-Tap
connector, connect white trigger wire to front door
ajar wire (Grey w/Red stripe). Run Yellow trigger
wire toward rear.
Power Step Trigger
Wire (White)
20
Power Step Trigger
Wire (Yellow)
Front Door Ajar
(Grey w/Red)
Driver Rear Door Ajar
(Light Green w/Yellow)
30
20
31
21
Passenger Rear Door Wiring: Using Posi-Tap
connector, connect Yellow trigger wire to rear door
ajar wire (Pink w/Light Blue stripe). This wire is
found rear of junction where wires route under front
passenger seat.
Note: Steps 13-23 are for model years 20022003 with factory remote keyless entry (the unlock
remote connected to your keys). For vehicles
without factory remote keyless entry, contact AMP
Research for additional instructions.
Yellow Power Step
trigger wire
32
22
rear door ajar
(Pink with Light Blue)
33
23
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
Secure wires and replace kick panel and sill plate.
Be careful not to pinch any wires when replacing
panels.
Plug in motors (both sides). Route remaining LED
light wires back towards rear of vehicle.
4
3
28
24
29
25
Slide mounting T-nut into position. Mount Board and
tighten fasteners to 10ft-lbs. Align the end of the
board with the rear edge of the back door.
On each side of the vehicle measure from the front
edge of door line on the pinch weld to the specified
lengths below. Measure at 27” for front LED Light
and 65” for rear LED LIght.
2
1
10
TORQUE
10 ft-lbs.
(13.5 Nm)
30
26
Drill a 9/32” hole through the pinch weld at marked
locations. Debur all holes.
27”
65”
27
31
Insert grommet into drilled holes. Insert lamp wires
through the grommets. (Silicon lube will help wires
slip through grommets.)
21
32
28
33
29
22
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
Affix lamp to rocker panel surface. Make sure lamp
is affixed to a flat, clean surface.
Using supplied butt connectors, connect the lamp
wires. Red to Red, Black to Black
22
30
Close and wrap with conduit and electrical tape.
Secure all loose wires with cable ties, with lamp
wires pulled upward to avoid any wire snagging.
31
Reinstall the fuse.
Replace fuse
32
4
33
A M P R E S E A R C H P O W E R S T E P TM – F O R D S U P E R D U T Y
Check that all doors activate the Power Step and the LED Lights work when doors
open and close. Reinstall any remaining trim panels.
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.
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.
AMP RESEARCH RUNNIG BOARDS
SIDE STEPS
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