AMP RESEARCH 77106-01A Running Board Installation Guide
- June 13, 2024
- AMP RESEARCH
Table of Contents
AMP RESEARCH 77106-01A Running Board
Product Information
This product is an installation guide for the AMP Research running board
assembly designed for Ford Super Duty – Crew Cab vehicles manufactured between
2002 and 2003. The AMP Part number for this product is 77106-01A. Please note
that this application only works on the Crew Cab model vehicles. The
installation time for this product is estimated to be between 3 to 5 hours,
and professional installation is highly recommended. The required skill level
for installation is rated at 4, which means it is recommended for experienced
individuals. Various tools are required for the installation, including safety
goggles, measuring tape, different socket sizes, ratchet wrench and extension,
wire crimpers, wire stripper/cutter, hex key wrenches, electrical tape,
weatherproof caulking, and silicone spray.
The product comes with a 5-Year Limited Warranty. For technical support,
customers can contact AMP Research at
1-888-983-2204 (Press 2) from Monday to
Friday between 7:00 AM – 5:00 PM PST. More information about the product can
be found on the AMP Research website at www.amp-research.com.
Product Usage Instructions
- Attach the motor to the linkage assembly following the provided exploded view diagram.
- Assemble the running board assembly using the provided components and dimensions shown in the diagram. Make sure to follow the instructions specific to the driver side.
- Set the rail into position and secure it using U-nuts, button head bolts, washers, and flange nuts as instructed in the diagram.
- Mount the motor linkage assembly and idler assembly according to the specific instructions for Super duty or Excursion models.
- Thread the supplied bolts into the rear drive linkage and front idler linkage, but do not tighten them at this stage.
These are the general usage instructions provided in the user manual. For detailed step-by-step installation instructions, please refer to the complete user manual or contact AMP Research technical support.
APPLICATION
Ford Super Duty – Crew Cab 2002 – 2003
Note: The application works only on the Crew Cab model Vehicles.
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
WARRANTY
5-Year Limited Warranty
AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday – Friday, 7:00 AM – 5:00 PM PST
Invented, engineered and manufactured exclusively by AMP Research in the USA. May be covered by one OR MORE of the following patents: 6,641,158; 6,830,257; 6,834,875; 6,938,909; 7,055,839; 7,380,807; 7,413,204; 7,398,985; 7,584,975; 7,566,064; 7,487,986; 8,157,277; 8,408,571; 9,302,626; 9,561,751; 10,053,017; CA2463717 ©2012 AMP Research. All rights reserved. Printed in USA.
AMP RESEARCH POWERSTEP XLTM – FORD SuperDuty
INSTALLATION GUIDE
Attaching motor to Linkage assembly.
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.
-
(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)
Running board assembly
Hardware
Assembly Instruction
Insert 7 Carriage bolts (17) into slot on rail (4). Insert from either end of
rail. Add 2 Light Brackets (29) 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 Flange Nuts (18), assemble Brackets 2x (30) & 1x (31) onto the rail (4),
using the carriage bolts (17) left from previous step. 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.
Note: Badge on rail sits towards the rear of the 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 Rear Drive Linkage. Repeat step for Front Idler Linkage. Do not tighten.
Install provided spacer (19) and M6 bolt (14) 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 4 to 16 ft-lbs. Next use a 10mm socket, torque linkage spacer bolt 2x (14) from step 5 to 8 ft-lbs. Once linkages are tight cycle board to verify steps deploy under own weight.
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.
Attach motor to harness. Using a 4mm hex Torque to 36 in-Lbs.
Torque bolts on mounting brackets as shown to 16ft-lbs.
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.
Puncture grommet and thread trigger wire
The Green and Green/Violet wires need to 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.
Remove driver side front door panel. This will require removing multiple
concealed bolts and paneling.
Door panel removal will require removal of door light lens and window corner
trim.
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.
Posi-Tap™ instructions
Driver Front Door Wiring: Using Posi-Tap™ (7) connector, connect the
supplied additional wire (Red) to front door ajar wire (Yellow w/Black stripe)
Driver Front Door Wiring: Using Posi-Tap™ (7) connector, connect the supplied
additional wire (Red) to front door ajar wire (Yellow w/Black stripe)
(See wiring guides and step-by-step instrctions; the correct wire will ground
when the rear door is closed and OL with the rear door open.
Passenger Front Door Wiring: Using Posi-Tap™ (7) connector, connect white
trigger wire to front door ajar wire (Grey w/Red stripe). Run Yellow trigger
wire toward rear.|
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.
For vehicles without factory remote keyless entry, contact AMP Research for
additional instructions. AMP Research Tech Support:
1-888-983-2204 (Press 2)
Connect harness to motor. Secure harness with tie wraps.
Affix LED lamp (23) to LED Bracket (29) as shown. 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.
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 Power Step 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, Power Step 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 restoring 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.
Thank you for your recent AMP Research Purchase.
REGISTER YOUR PRODUCT TODAY FOR FASTER SERVICE & PRODUCT UPDATES
Please visit:
www.amp-research.com/productregistration or scan the QR Code
Product Registration Benefits:
- Ensure we have your purchase receipt and product info in our system which is required for warranty
- Faster and easier access to customer service and tech support in the unlikely event you need warranty or product support
- Registration helps us keep you up to date on product information and offers
To view other Amp Research products that may be offered for your vehicle. Please visit: www.amp-research.com
Congratulations on your purchase of the genuine AMP Research Power Step !
Here’s what you should know…
AMP Research PowerStep running boards automatically move when the doors are
opened to assist entering and exiting the vehicle.
-
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.
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 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 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
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
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>