AMP RESEARCH 77141-01A Power Step XL Running Board Installation Guide
- June 13, 2024
- AMP RESEARCH
Table of Contents
AMP RESEARCH 77141-01A Power Step XL Running Board
TOOLS REQUIRED
- Safety goggles
- Measuring tape
- 10 mm socket
- 13 mm socket
- 1/2” socket
- Ratchet wrench and extension
- Wire crimpers
- Wire stripper / cutter
- 3/16” hex key wrench (allen wrench)
- 4mm hex key wrench (allen wrench)
- Electrical tape
- Weather proof caulking (silicone sealer)
- Silicone spray
- 5/32” Allen key
WARRANTY: 5-Year Limited Warranty
EXPLODED VIEW
- Motor
- Socket cap screw
- Washer
- 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:
- Position the gear cover in place as shown if not already in place.
- Seat motor into position on the three mounting bosses. This may require an adjustment of the gear by moving the swing arms.
- 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.
PARTS
INSTALLATION INSTRUCTION
-
Locate mounting points. First 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 washer (15) on outside and provided M8 nuts on the backside. Do not tighten.
-
Insert 7 Carriage Bolts (17) into slot on Rail (4). Insert from either end of rail. Add 2 Light Brackets (25) on the 3rd and 5th bolt. Insert Flange Nut (18) onto bracket tab to attach light brackets into position shown. Leave loose to allow for adjustment.
-
Using provided captive washer M8 bolts (8) install upper bracket hardware to brackets. Do not tighten.
-
Set Rail up into position. Using the carriage bolts that are on the rail, attach the brackets starting with the rear bracket and work to the front bracket. Use 5 Flange Nuts (18) to attach the brackets to the carriage bolts. 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 not tighten.
Note: Badge on rail sits towards the rear of vehicle! -
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) first to16ft-lbs. Next tighten upper sill bolts (8) to 16ft-lbs. Next torque flange bolt and nut on bracket tab to 16ft-lbs.
-
Thread supplied bolts 2x (8) into Front Idler Linkage. Repeat step for Rear Drive Linkage. Do not tighten.
-
Install provided spacer (19) and M6 bolt (12) into upper mount as shown on both the Drive and Idler linkages. Do not tighten.
-
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 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.
-
Attach motor to harness. Using a 4mm hex Torque to 36 in-Lbs.
-
Remove fuse from wire harness.
-
Attach wire harness to controller (make sure connector locking tabs fully engage). Mount controller with the two 11” tie wraps to factory conduit.
-
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 down along driver-side wheel well and along frame of vehicle. Secure with tie wraps.
-
Remove driver-side front kick panel and door sill plate. Roll back carpet to access hole for passing trigg er wires into cab of vehicle.
-
Connect harness to motor. Secure harness with tie wraps.
-
Affix LED lamp (23) to Light Bracket (25) on rail. Slide bracket into desired position and tighten using 5/32” Allen key.
-
Using supplied butt connectors (24), 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.
-
OBD II install: Use Supplied Posi Twist connectors to attach the Plug and Play Module to the Harness. Attach matching colors on the harness to the wires on the module. Plug in module to OBD II port on the vehicle. Secure harness with supplied tie wraps.
Note: If the OBD II pass thru harness (76404-01A) was purchased see install sheet supplied in packaging. The pass through harness allows for an open port for other accessories. See next page for a brief description.
-
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 illuminated by closing and opening any door of vehicle.
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May be covered by one OR MORE of the following patents: 6,641,158; 6,830,257;
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