AMP RESEARCH 2021-2022 Ford Bronco 4 Door Installation Guide

AMP RESEARCH 2021-2022 Ford Bronco 4 Door

Product Information

• Product Name: Ford Bronco 4 Door
• Model Year: 2021-2022
• AMP Part #: 77140-01A
• Installation Time: 3-5 Hours
• Skill Level: 4 (Experienced)
• Warranty: 5-Year Limited Warranty
• AMP Research Tech Support: 1-888-983-2204 (Press 2), Monday – Friday, 7:00 AM – 5:00 PM PST
• Website: www.amp-research.com

Product Usage Instructions

Attaching motor to Linkage assembly

CAUTION:
HANDLE WITH CARE. 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.

Note: For a detailed parts list and hardware identification, please refer to the user manual.

If you have any questions or need further assistance, please contact AMP Research Tech Support at 1-888-983-2204 (Press 2) during the hours mentioned above.

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
• Weatherproof caulking (silicone sealer)
• Silicone spray
• 5/32” Allen Key

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 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:

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 a 4mm Hex Head. Tighten screws to 36 in-lbs (4N-m). Do not over-torque.

PARTS LIST AND HARDWARE IDENTIFICATION

Installation Instruction

1. Locate the Front Idler linkage location. If plastic plugs are present remove plastic plugs to expose threads.

2. Attach bracket (27) using M10 Hex Flange Bolts (8).
   The driver’s side is shown.

3. Locate the Rear Drive linkage location. If plastic plugs are present remove plastic plugs to expose threads.

4. Attach bracket (28) using M10 Hex Flange Bolts (8).
   The driver’s side is shown.

5. Insert 6 Carriage bolts (#12) into the slot on the rail (#2) from either end of the rail. Add Light Bracket (#14) on the 3rd and 4th bolts. Insert Flange nut (#13) onto the bracket tab to attach light brackets (14) into the position shown. The dimensions shown are for reference. Leave loose to allow for adjustment.
   The driver’s side is shown.

6. Set the rail up into position, center in the rocker panel area. Starting with the rear bracket, work towards the two front brackets. Insert Flange nut (13) to bolts to attach rail to brackets.

   • Start from the rear of the vehicle and torque 4x M10 Flange Nuts (13) to 16 ft-lbs.
   • Note: DO NOT TORQUE nuts holding light brackets. They will be tightened in step 18.

7. Mount front drive linkage onto a rear location on the driver’s side. Thread supplied M8 Hex bolts (#9) into the front-drive linkage. Repeat the step for Front idler linkage.

   • Note: The motor faces towards the front of the vehicle on the driver’s side and rear on the passenger side.
   • Do not tighten.

8. Install the provided Spacer (15) and M6 Bolt (10) into the upper mount as shown on both the Drive and Idler linkages. Do not tighten.

9. Slide mounting T-nut into position, Center board in rail pocket. Tighten Socket Cap screws (11) to 10 ft-lbs.

10. Using a 13mm socket Torque linkage bolts 4x (9) from step 5 to 16 ft-lbs.

    • Next use a 10mm socket, torque linkage spacer bolt 2x (11) from step 6 to 8 ft-lbs.
    • Once linkages are tight cycle board to verify steps deploy under own weight.

11. Remove fuses from Power Step Wire Harness (6). Mount controller using supplied zip ties (17) to harness (6) 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.

12. 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. Secure harness with Zip Ties (16).

13. Locate the oval grommet on the driver side of the firewall and push out. Poke a small hole in the grommet and thread trigger wires into the cab of the vehicle.

14. Locate the following wires and connect with the supplied Posi-Tap™ (26) to the following wire colors listed below.

15. Wire OBD II connector with Posi-Lock™ (25)
    OBD II Connector is located below the steering column.

    • OBD II install: Use Supplied Posi-Lock™ (25) 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.

16. Attach motor to linkage. Using a 13mm wrench Torque to 36 in-lbs.

    • See page 2 for further instructions on attaching the motor to the linkage.
    • Note: The motor on the driver’s side faces the front of the vehicle and the passenger faces toward the rear of the vehicle.

17. On the driver’s side, run the Wire Harness leg down and along the underside of the vehicle floor and frame to the rear Drive Linkage. Connect the harness to the motor and secure the harness with tie wraps.

18. Affix LED Lamp (18) to Light Bracket (14) on the rail. Slide the bracket into the desired position and tighten using the 5/32” Allen key.

19. Using supplied butt connectors (19), 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 zip ties (16). Pull lamp wires upward to avoid any wire snagging.

20. Check that all doors activate the Power Step and that 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 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.

REGISTER YOUR PRODUCT TODAY FOR FASTER SERVICE AND 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
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To view other Amp Research products that may be offered for your vehicle.

• Please visit  www.amp-research.com.

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.

LIMITED 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 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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