AMP RESEARCH 76138-01A Running Board Assembly Installation Guide

AMP RESEARCH 76138-01A Running Board Assembly

Product Information

This product is an installation guide for the AMP Research PowerStep Running Boards for various models of Dodge Ram trucks. It is compatible with the following models and years:

• Dodge Ram Regular Cab – 2013-2015
• Dodge Ram Quad Cab – 2013-2015
• Dodge Ram Crew Cab – 2013-2015
• Dodge Ram Mega Cab – 2013-2015
• Dodge Ram 1500 2500/3500 – 2013-2015

Please note that modification is required for the running board assembly of the Regular Cab and Crew Cab models. Chassis Cab models with diesel engines are excluded from compatibility.

• The product comes with a 5-Year Limited Warranty and professional installation is recommended. The estimated installation time is 3-5 hours. The required skill level is rated from 1 to 4, with 4 indicating an experienced level.
• The tools required for installation include safety goggles, measuring tape, wrenches of different sizes, socket set, ratchet wrench, wire stripper/cutter, hex keys, rivet tool, drill bits, torx bit, center punch, anti-corrosion paint, and electrical tape.
• For any technical support or assistance, customers can contact AMP Research at 1-888-983-2204 (Press 2) from Monday to Friday between 7:00 AM to 5:00 PM PST. More information can be found on their website at www.amp-research.com.

Product Usage Instructions

Motor to Linkage Assembly
Before continuing with the installation, the motor needs to be attached to the linkage assembly. Follow the instructions below:

1. Position the gear cover in place as shown, if it’s not already in place.
2. Seat the motor into position on the three mounting bosses. Adjust the gear by moving the swing arms if necessary.
3. Fasten the motor with the three motor mount screws using a 4mm Hex Head. Tighten the screws to 36 in-lbs (4N-m). Do not over torque.

Parts List and Hardware Identification
The following is the list of parts and hardware included with the product:

• Running Board Assembly
• End caps (1 left & 1 right)
• T-Nut Insert (x2)
• S-style clips (x2)
• Driver Side Linkages
• Motor Linkage Assembly – Driver-Side
• Idler Linkage Assembly – Driver Side
• Idler Linkage Assembly – Passenger Side
• Motor Linkage Assembly – Passenger Side
• Wire Harness
• STA Controller
• Rivet Nut (x8)
• Rivet Nut Tool
• Conical Washer Bolt (x20)
• Blind Rivet (x8)
• Socket Cap Screw (x8)
• Cable Tie (7) (x20)
• Cable Tie (11) (x2)
• Posi-LockTM Connector (x2)
• Button Head Torx Screw (x8)
• Washer (x8)
• Grommet (x4)
• LED Lamp
• Butt Connector (x8)
• Reinforcement Bracket (x4)
• Blind Rivet (x4)
• OBD II Plug
• Spacer (front drive linkage) (x2)
• Motor kit (x2)
• Front Body Mount (for 1500 models only)

APPLICATION

APPLICATION/MODEL YR/PART #

• Dodge Ram Regular Cab * 1500 2013 – 2015 76138-01A REV B
• Dodge Ram Quad Cab * 1500 2013 – 2015 76138-01A REV B
• Dodge Ram Crew Cab 1500 2013 – 2015 76138-01A REV B
• Dodge Ram Regular Cab * 2500/3500 2013 – 2015 76138-01A REV B
• Dodge Ram Crew Cab 2500/3500 2013 – 2015 76138-01A REV B
• Dodge Ram Mega Cab 2500/3500 2013 – 2015 76138-01A REV B

NOTE: EXCLUDES CHASSIS CAB MODELS WITH DIESEL ENGINES.

INSTALLATION TIME

3-5 Hours
Professional installation recommended

SKILL LEVEL

• 4= Experienced

TOOLS REQUIRED

• Safety goggles
• Measuring tape
• 13mm wrench
• 19mm wrench
• 13mm socket
• 10mm socket
• Ratchet wrench and extension
• Wire stripper/cutter
• 3/16” hex key (Allen wrench)
• 4mm hex key (Allen wrench)
• Rivet Tool
• 1/8”, 9/32” and 3/16” Drill Bit
• T27 Torx Bit
• Center Punch
• Anti Corrosion Paint
• Electrical tape

WARRANTY
5-Year Limited Warranty

AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday – Friday, 7:00 AM – 5:00 PM PST

Motor to the linkage assembly

NOTE: The motors will be attached

EXPLODED VIEW

• Motor kit
• Socket cap screws
• Motor Linkage assembly

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 the 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.

PARTS LIST AND HARDWARE IDENTIFICATION

Note: Some Applications require modification.

Application

• Crew Cab, Mega Cab
• Quad Cab
• Regular Cab

Cut Length

• 79” (No Modification Required)
• 72” (Trim 7”)
• 50” (Trim 29”)

INSTALLATION INSTRUCTION

NOTE:

1500 RAM Only!
Powerstep installations require additional steps and come with the required additional hardware. Please read and carefully follow the instructions in Step 1 for your vehicle model. Follow Steps 1-5 to relocate the brake cable and wire harness plug and then proceed with the Power Step installation. For Ram 2500/3500 Skip to step 6.

1. 1500 RAM ONLY. On the driver’s side of the vehicle towards the front of the body remove the harness bracket with 10mm socket or wrench. Remove the plug from the bracket. And replace with supplied bracket (32) using two of the three factory screws.

2. 1500 RAM ONLY. While holding the brake cable adjustment nut with a wrench (located on the driver’s along the frame, towards the rear), loosen the brake cable to allow for slack. Mark the position of the nut before loosening.

3. 1500 RAM ONLY. After gaining enough slack, detach the brake cable as shown below. This detachment point is located just to the rear of the adjustment nut.

4. 1500 RAM ONLY. Remove the brake cable guide from the frame by depressing the locking tabs and sliding the guide out through the hole. Unthread the brake cable from the frame mount.

5. 1500 RAM ONLY. Attach brake cable guide to supplied Brake Cable Bracket (31) and mount bracket with supplied hardware. Reattach the brake cable and readjust the brake cable adjustment nut to
   HARDWARE MOUNTING OVERVIEW (passenger side shown)

6. Locate forward most and rearward most mounting provisions on the inner sill of the truck. Remove tape from the sill drain hole at both mounting points.
   Note: Some vehicles may have Front-welded fasteners installed already. Backing plates and rivet nuts are not needed in these locations. Factory Rivet nuts will need to be removed to install backing plates
   NOTE: Driving Linkage Assemblies (with motor) mount in the front; Idler Assemblies mount in the rear.

7. Set the Reinforcement Plate in place and locate it with rivet nuts. Drill the hole using a 1/8” drill bit. After drilling apply paint to prevent rusting

8. Once the hole is drilled insert a piece of string or wire through the hole in the Reinforcement Plate. Set the plate into position.

9. Set rivet nuts into place for alignment. Insert pop rivet through a hole in the plate and secure it in place. Once the pop rivet is installed remove the string or wire from the Reinforcement Plate. NOTE: Verify plate is pulled flush to the body before securing pop rivet.

10. Assemble Hex Bolt (lubricated with soapy water), Washer, Rivet Tool, and Rivet Nut together as shown and place into hex cutouts in the sill. An extra Hex Bolt and M8 Washer are supplied to install rivet nuts.

11. With the Rivet Nut Tool held in place with a 19mm wrench, tighten the Hex Bolt until the Rivet Nut deforms and secures itself to the sheet metal (110 in-lbs. or 4 turns). Remove Hex Bolt and Rivet Nut Tool. Repeat for each of the four mentioned mounting locations.

12. Once rivet nuts are in place use a screwdriver to push back the tab in the hole to avoid interference with the linkage mount.

13. Rear Linkage Install: Set the rear body mount plate (27) to the body.
    Note: Center and rear hole will be used. The driver’s side is shown. Use supplied Conical washer bolts (9) to attach as shown, At the pinch weld Use a T27 Torx driver and torque bolts to 6ft-lbs. Next torque bolts to 16 ft-lbs .

14. Rear Idler linkage: Set linkage into position. Use supplied conical washer bolts to attach the linkage to the body mount plate. Use the rearmost bolts as shown on the driver’s side. The passenger side will use the rear mount position as well. Torque bolts to 16ft-lbs.

15. Set the front body mount plate (26) to the body. The driver’s side is shown. Use supplied Conical washer bolts to attach as shown, At the pinch weld Use a T27 Torx driver and torque bolts to 6ft-lbs. Next torque bolts to 16 ft-lbs.

16. If the crash bracket is not present use supplied spacer (24) in place of the bracket. The spacer can be inserted after the body mount is up into position. The spacer will be held in place by drilling and pop riveting into place.

17. Rivets will be installed in steps 39 & 40.

18. Front Drive Linkage: Use 3 of the supplied conical washer bolts (8) to attach linkage to the body mount plate. Torque bolts to 16ft-lbs.

19. The jogs in the lower part of the linkages point toward one another, as shown by the drive (motor) Linkage in the Front and Idler Linkage in the Rear. Note: The linkage position is described in the parts list on page 3.

20. Install boards: Slide mounting T-Nut of the board into position and attach to linkages. Shift the board forward as much as possible for proper clearance. The end of the board/end cap will nest into the linkage lower mount 1/2” when positioned correctly.

    • With boards in extended position step on boards to seat linkages. Walk the length of the board taking bouncing steps. DO NOT JUMP ON BOARD! Verify that board end caps do not contact the pinch weld.
    • If Endcaps make contact loosen 4 button head screws at pinch weld. Walk the length of the board and apply weight to the center of the board and while applying weight retighten button head screws at pinch weld.
    • For instructions on how to adjust the board due to pinch weld Interference, scan the QR Code to watch the video, or type the following link to your browser: https://youtu.be/ITbAeixVKdQ.

21. Prepare large tie-wraps for mounting the Power Step Controller. Loosely loop tie-wraps around a large bundle of wires behind the battery in the engine compartment.

22. Insert the controller into tie-wrap loops and cinch down securely. The tie-wraps should cinch down into channels on the controller surface.

23. Remove the fuse from the Power Step Wire Harness.
    Connect power leads from the Controller, Red to the positive battery terminal, and Black to the vehicle body ground as shown.

24. Locate a large rubber wire boot on the driver-side firewall as shown below. Slice a small opening as shown below to run trigger wires through.

25. Tape the leading end of the wires together and push through the rubber boot to the cabin side of the firewall. Silicon lubricant may be used for ease of passage. The trigger wires will come out just above and to the left of the brake pedal.

26. OBD II Connector located below the driver-side steering column.

27. 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 the harness with supplied tie wraps.

    • Note: If the OBD II pass-thru harness (76404-01A) was purchased see the install sheet supplied in the packaging. The pass-through harness allows for an open port for other accessories. See below for a brief description.

28. Route the two Wire Harness legs down over the wheel wells toward Motor Linkages, long leg across to the passenger side. Secure harness with tie wraps (13).

29. Using a 4mm hex key torque bolts to 36 in-lbs. See page 2 for motor installation instructions.

30. On the driver’s side, run the Wire Harness leg down and along the underside of the vehicle floor and frame to the front Drive Linkage. Connect the harness to the motor and secure the harness with tie wraps. Route remainder of wire harness towards rear linkage assembly for LED lights

31. On the Passenger Side, run the Wire Harness leg down and along the underside of the vehicle floor and frame to the front Drive Linkage. Connect the harness to the motor and secure the harness with tie wraps. Route remainder of wire harness towards rear linkage assembly for LED lights

32. On each side of the vehicle measure from the front edge of the door line on the pinch weld to the specified lengths below. Measure at 22” for the front LED Light and 64-3/4” for the rear LED Light. Note for Quad cabs mount lights at 22” and 54” for Regular cabs mount lights at 10” and 45”.

33. Drill a 9/32” hole through the pinch weld at marked locations. Deburr all holes. After drilling apply paint to holes to prevent rusting

34. Insert the grommet into drilled holes. Insert lamp wires through the grommets. (Silicon lube will help wires slip through grommets.)

35. Affix the lamp to the rocker panel surface. Make sure the lamp is affixed to a flat, clean surface.

36. Using supplied butt connectors, connect the lamp wires. Red to Red, Black to Black. Once Crimped use a heat gun to shrink the tube.

37. 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.

38. With linkage resting square on the hex bolts Using a 3/16” Drill bit, drill both upper holes in linkage through sheet metal. After drilling apply paint to holes to prevent rusting.

39. Using a Rivet Gun install rivets.

40. Reinstall the fuse to the Powerstep harness. Check that all doors activate the Power Step and that the LED Lights work when doors open and close. Reinstall any remaining trim panels.

41. FINAL SYSTEM CHECK
    Check that all doors activate the PowerStep and that 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
  *  **CORRECT OPERATION OF LIGHTS:** All four lamps will illuminate upon opening any door of the vehicle. Lamps will stay on until the restoration of both Power Steps or until 5 minutes has expired with the doors open. When the lights time out after 5 minutes, they can be illuminated by closing and opening any door of the vehicle.

Thank you for your recent AMP Research Purchase.

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POWER-DEPLOYABLE RUNNING BOARDS OPERATION:
AMP Research PowerStep running boards automatically move when the doors are opened to assist in entering and exiting the vehicle.

• Automatic power deployment:
  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.

5-YEAR LIMITED WARRANTY

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 specified. The decision to repair or replace is wholly within the discretion of the manufacturer.

• This warranty specifically excludes labor. If you have a warranty claim, first you must call our factory at the number below 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, fire, vandalism, negligence, misinstallation, misuse, Acts of God, or 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 specific 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 TECH SUPPORT 1-888-983-2204

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.

The material that your product is made from can be recycled. Please also consider recycling the packaging that your product came in.

References

• AMP Research Accessories | RealTruck
• RealTruck Warranty Registration | RealTruck

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