AMP 78140-01A Running Board Assembly Instruction Manual
- June 13, 2024
- AMP
Table of Contents
- AMP 78140-01A Running Board Assembly
- Product Information
- Product Usage Instructions
- Locate the Rear Drive linkage location
- TOOLS REQUIRED
- EXPLODED VIEW
- Instructions
- COMPONENT/PARTS IDENTIFICATION
- Installation Instructions
- WARRANTY
- CONTACT
- References
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
AMP 78140-01A Running Board Assembly
Product Information
- Application: Ford Bronco 4 Door, Ford Bronco 2 Door
- Length: 72″ (for Bronco 4 Door), 55″ (for Bronco 2 Door)
- Model Year: 2021 – 2023
- Part Number: 78140-01A
- Installation Time: 3-5 Hours
- Skill Level: 4 (Experienced)
- Tools Required: Safety goggles, Measuring tape, 10 mm socket, 10 mm ratchet wrench, 13 mm ratchet wrench, 15 mm ratchet wrench, Ratchet wrench and extension, Pliers, Wire crimpers, Wire stripper/cutter, 3/16 Hex key wrench (Allen wrench), Electrical tape, Weatherproof caulking (silicone sealer), 1/8 Drill bit, 9/32 Drill bit, Drill, Heat Gun, 6″ Extension
- Warranty: 5-Year Limited Warranty
Product Usage Instructions
Attaching motor to Linkage assembly
CAUTION: HANDLE WITH CARE
To ensure our customers receive all components with full integrity, we pack the motors separately from their Linkage assemblies. This requires that the installer position and fasten the motor before continuing with the installation. Please follow the instructions below and handle the assembly carefully.
CAUTION: Dropping the assembly or any excessive impact MAY cause damage to the motor.
- Position the gear cover in place as shown if not already in place.
- Seat the 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 a 4mm Hex Head. Tighten screws to 36 in-lbs (4N-m). Do not over-torque.
Note: Some Applications require modification.
Component/Parts Identification
Refer to the provided diagram for component/parts identification.
Locate the Front Motor linkage location
- If plastic plugs are present, remove plastic plugs to expose threads.
- Pre-thread supplied M10 flange bolt and hook linkage (3) over bolt as shown.
- Once the linkage is in position, thread in the rear linkage mounting bolt (13). Snug up bolts but do not torque.
- Note: The motor will face towards the rear of the vehicle.
Locate the Rear Drive linkage location
- If plastic plugs are present, remove plastic plugs to expose threads.
- Pre-thread supplied M10 flange bolt (3) and hook linkage over bolt as shown.
- Once linkage (2) is in position, thread in the rear linkage mounting bolt. Snug up bolts but do not torque.
APPLICATION LENGTH MODEL YR PART #
- Ford Bronco 4 Door 72” 2021 – 2023 78140-01A
- Ford Bronco 2 Door 55” 2021 – 2023 78140-01A
INSTALLATION TIME
- 3-5 Hours
- Professional installation recommended
SKILL LEVEL
- 4= Experienced
TOOLS REQUIRED
- Safety goggles
- Measuring tape
- 10 mm socket
- 10 mm ratchet wrench
- 13 mm ratchet wrench
- 15 mm ratchet wrench
- Ratchet wrench and extension
- Pliers
- Wire crimpers
- Wire stripper/cutter
- 3/16” H hex key wrench (Allen wrench)
- Electrical tape
- Weatherproof caulking (silicone sealer)
- 1/8” Drill bit
- 9/32” Drill bit
- Drill
- Heat Gun
- 6” Extension
INSTALLATION GUIDE
- Attaching motor to Linkage assembly
- The motors must be attached to the Linkage assemblies on step 5
EXPLODED VIEW
- Motor
- Socket cap screw
- Motor Linkage assembly
- Cinch Fastners
CAUTION: HANDLE WITH CARE.
To ensure our customers receive all components with full integrity, we pack
the motors separately from their Linkage assemblies. This requires that the
installer position and fasten the motor before continuing with the
installation. 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 the 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.
Note: Some Applications require modification.
Application Cut Length
- Bronco 4 Door 72” (No Modification Required)
- Bronco 2 Door 55” (Trim 17”)
COMPONENT/PARTS IDENTIFICATION
Installation Instructions
-
Locate the Front Motor linkage location. If plastic plugs are present remove plastic plugs to expose threads.
-
Pre-thread supplied M10 flange bolt and hook linkage (3) over bolt as shown. Once the linkage is in position thread in the rear linkage mounting bolt (13). Snug up bolts but do not torque.
Note: The motor will face towards the rear of the vehicle. -
Locate the Rear Drive linkage location. If plastic plugs are present remove plastic plugs to expose threads.
Pre-thread supplied M10 flange bolt (3) and hook linkage over bolt as shown. Once linkage (2) is in position thread in rear linkage mounting bolt. Snug up bolts but do not torque.
Install Running Board (1) to linkages.
Measure approx. 9.5” from the back of the linkage to the tip of the board.
In order to prevent binding follow the steps below.
Note: Handcycle Boards between each step.
- Tighten socket cap screws (10) with a 3/16” Allen wrench. Torque to 10ft-lbs.
- Rear Linkage: Tighten and torque Linkage upper mount bolt closest to pinch weld Torque to 30ft-lbs.
- Front Linkage: Tighten and torque the Linkage upper mount bolt closest to the pinch weld. Torque to 30ft-lbs
- Rear Linkage: Tighten and torque the Linkage upper mount bolt closest to the floor of the cab. Torque to 30ft-lbs.
- Front Linkage: Tighten and torque the Linkage upper mount bolt closest to the frame of the truck. Torque to 30ft-lbs.
- Handcycle boards to ensure no bind is present.
- Install motor onto linkages using supplied Hex head bolts (18). Torque to 36in-lbs. ( for motor install)
- Remove the Fuse from powerstep wire harness.
- Mount controller using supplied zip ties to harness in front of battery as shown. Connect positive leads from the harness. Red to the positive battery terminal and black to the negative battery terminal.
- Route the two wire harness legs down over to each wheel well. The long leg will run across to the passenger side, short leg will run down to the driver’s side. Ensure the loom is free from steering and exhaust components.
- Peel back a small conduit with 2 purple wires inside to approx. 8” from junction. Trim excess conduit and tape end. This will allow wires to be exposed beyond the grommet when inserted into the cab of the vehicle. Excess wire will need to be trimmed for this application after being inserted into the vehicle.
- Locate the oval grommet on the driver side of the firewall and push out. Poke a small hole in grommet and thread trigger wires into cab of the vehicle.
- Locate the following wires and connect with the supplied Posi-Tap™ to the wire colours listed below.
Factory Can Wire OBD Module wire Color
- Grey with Orange Stripe White Wire
- Purple with Orange Stripe Blue Wire
Wire OBD II connector with Posi-Splice.
OBD II Connector located below the steering column.
OBD II install: Use Supplied Posi-Lock™ connectors to attach the Plug and Play Module to the Harness. Attach matching colours 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.
For 4 Door Bronco and Ranger. 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 16” for the front LED Light and 58” for the rear LED
NOTE: For 2 Door Bronco, measure at 16” for the front LED Light and 38” for the rear LED Light.
-
Drill a 9/32” hole through the pinch weld at marked locations. Deburr all holes. After drilling apply paint to
holes to prevent rusting. – Insert grommet into drilled holes. Insert lamp wires through the grommets. (Silicon lube will help wires slip through grommets). -
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. Once Crimped use a heat gun to shrink the tube. 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.
Insert plug from wire harness (4) onto motor (7). Slide rubber grommet on wire
harness into slot of motor cover (8). Insert the motor cover onto the motor.
Use electrical tape to cover any exposed wire from the motor.
Insert plastic push pin rivets (14) in mounting holes of motor cover (8). Use
pliers to ease installation.
NOTE: On 2-door Bronco, tie up extra wires using supplied zip ties (15)
to avoid wire snagging.
- Reinstall Fuse. 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 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 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 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 timeout 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 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:
- The running boards can be manually set in the deployed position by firmly holding the step down with 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 the deployed position and flush the front and rear hinge arms with a high-
- pressure car wash wand.
- 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.
WARRANTY
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 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.
CONTACT
- 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.