AMP 78242-01A Running Board Assembly Installation Guide

AMP 78242-01A Running Board Assembly

Product Information

The product is an installation kit designed for Ford Super Duty SuperCab and SuperCrew models. It is compatible with SYNC 4 Vehicles and is suitable for trim levels including Lariat, King Ranch, Platinum, and Limited Models. The installation time is estimated to be 2-3 hours, and professional installation is recommended. The product comes with a 5-Year Limited Warranty and is supported by AMP Research Tech Support.

Parts List:

1. Running Board assembly
   • End caps (1 left & 1 right)
   • T-Nut Insert (x2)
   • S-style clips (x2)
2. Front Motor linkage assembly
3. Rear Motor linkage assembly
4. Wire harness
5. Controller XTA
6. Motor (x4)
7. Socket cap screw (x8)
8. Nut with Conical washer (x13)
9. Grommet (Only needed on RegularCab and SuperCab)
10. Gear Cover (x4)
11. LED Light (x4)
12. Butt Connector (x8)
13. Cable Ties 7 (x20)
14. Cable Ties 11 (x2)
15. ODB II Plug
16. Posi-LockTM (Grey) (x2)
17. Posi-TapTM (Red/Black) (x2)
18. Bracket
19. Hex Bolt w Conical washer (x4)

Tools Required:

• Safety goggles
• 8 mm socket
• 10 mm socket
• 13 mm socket
• 13 mm end wrench
• Ratchet wrench and extension
• Wire stripper
• 9/32 & 19/64 Drill Bit
• 3/16 hex key wrench (allen wrench)
• 4mm hex key wrench (allen wrench)
• Electrical tape
• Weatherproof caulking (silicone sealer)
• Drill
• Heat Gun

Product Usage Instructions

Attaching motor to linkage assembly:

The motors must be attached to the linkage assemblies before continuing the installation process. Follow the instructions below:

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 using a 4mm allen wrench. Tighten screws to 36 in-lbs (4N-m). Do not over torque.

Relocate Brake Cable Guide:

To relocate the brake cable guide, follow the steps below:

1. Locate the rearmost brake cable guide bracket and remove using a 13mm Socket or wrench.
2. Use the supplied relocation bracket (19) and mount it to the
   frame as shown. Attach the factory guide to the bracket using the supplied Bolt (20) and nut (8).

Please refer to the user manual for more detailed instructions and illustrations.

Note: Only compatible with SYNC 4 VehiclesTrim levels include: Lariat, King Ranch, Platinum & Limited Models.

INSTALLATION TIME
2-3 Hours
Professional installation recommended

SKILL LEVEL

4= Experienced

TOOLS REQUIRED

• Safety goggles
• 8 mm socket
• 10 mm socket
• 13 mm socket
• 13 mm end wrench
• Ratchet wrench and extension
• Wire stripper
• 9/32” & 19/64” Drill Bit
• 3/16” hex key wrench (allen wrench)
• 4mm hex key wrench (allen wrench)
• Electrical tape
• Weather proof caulking (silicone sealer)
• Drill
• Heat Gun

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.

INSTALLATION GUIDE

Attaching motor to linkage assembly
The motors must be attached to the linkage assemblies before continuing the installation process.

CAUTION: HANDLE WITH CARE.

To insure 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 allen wrench. Tighten screws to 36 in-lbs (4N-m). Do not over torque.

PARTS LIST AND HARDWARE IDENTIFICATION

Relocate Brake Cable Guide as shown in the following steps:

1. A. Locate rearmost brake cable guide bracket and remove using a 13mm Socket or wrench.
   B. Use supplied relocation bracket (19) and mount to frame as shown. Attach factory guide to bracket as shown using supplied Bolt (20) and nut (8).

2. Locate mounting points; first and last set of studs on the inner sill.
   Motor Linkage mounts toward the front of the truck and Idler mount toward the rear. Driver side shown below.

3. Mount drive and Idler linkage assemblies. Repeat for passenger side. Make sure linkages sit square, fully resting on studs before tightening. Torque to 16 ft. lbs (22Nm)

4. Remove fuse from wire harness
5. Attach wire harness to controller (make sure connector locking tabs fully engage). Mount controller with the two 11” tie wraps to factory conduit, just forward of battery.

6. Route shorter leg of harness down passenger-side wheel well and longer leg of harness down along driver side wheel well. Secure with tie wraps.

7. Attach harness ground to body ground located on inner fender. Connect red leads to positive terminal on battery.
8. Route factory harness underneath vehicle and plug in motors (both sides). Route remaining LED light wires back towards rear of vehicle.

9. Remove driver side front kick panel and door sill plate. Roll back carpet to access hole for passing trigger wires into cab of vehicle.

10. On Crew Cab models, remove grommet in floor panel above front linkage on driver side. Poke small hole into grommet and thread the two trigger wires through and up into the cabin of vehicle. Seal grommet with silicone sealer.
11. Super Cab models, use a 9/32” drill bit to drill hole through floor and insert grommet (#9) that is supplied with kit. Thread the wires through and apply silicone sealant.

12. Locate black module just above e-brake pedal, and proceed to remove it for easier access. To remove module from bracket, push tab as shown and slide bracket downward.

13. Locate the following wires (black connector) and connect the blue and white wires of the Powerstep Connection Module with supplied Posi-Tap™ (18) to the following wire colors listed below.

14. Use supplied Posi-Lock™ (17) to attach the 2 purple wires of the OBD harness to the main harness. Attach matching colors on the harness to the wires on the module. Lastly reinstall Factory OBD port removed in step 12. Plug in module to OBD port on the vehicle. Reinstall sill plate removed from step 9.

15. OBD II install: Use Supplied Posi-Lock™ 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 below for a brief description.

16. Attach step, sliding the mounting T-nut into position. Torque to 10 ft lbs (13.5 Nm)
17. On each side of the vehicle measure from the rear linkage to end of the board. Measurement should be approximately 11” as shown below.

18. On each side of the vehicle use tape to mark the led drill location two sections from studs as shown below. Use tape to indicate. Locations are approximately 22” & 66” from front door edge.

19. Mark hole location 1/2” midpoint of the rocker with tape and center punch and drill 19/64” hole into pinch weld. Deburr hole and insert grommet (#12) for LED Wire.
20. Route LED wires though through grommet, clean surface, and stick on to rocker panel as shown below.

21. Using supplied butt connectors, connect the lamp wires. Red to Red, Black to Black. Heat the shrink tubing on the connecters to seal wires.
22. 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.

23. 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.

AMERICAN DESIGNED, ENGINEERED AND MANUFACTURED.

Thank you for your recent AMP Research Purchase.
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• Ensure we have your purchase receipt and product info in our system which is required for warranty
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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 PowerStep!Here’s what you should know…

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.

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 CUSTOMER SERVICE 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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