Ford - F 150 Super Crew - Workshop Manual - 2009 - 2009

INSTALLATION GUIDE APPLICATION Ford F150 SuperCab Ford F150 SuperCrew LENGTH 72”’ 79” MODEL YR PART # Bestop PART# 2009 2009 10-02996-31 10-02996-32 75140-01 75141-01 INSTALLATION TIME 3:00 hrs SKILL LEVEL 1 2 3 4 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 ‰ 3/16” hex key wrench ( allen wrench) ‰ 4mm hex key wrench ( allen wrench) ‰ Electrical tape ‰ Weather proof caulking ( silicone sealer ) AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday - Friday, 7:00 AM - 4:00 PM PST Designed and manufactured by AMP Research®. Patent Number 6,830,257; 6,641,158; 6,834,875; 6,938,909; 6,942,233; 7,007,961; 7,055,839; 7,163,221; 7,367,574; 7,380,807; 7,398,985; 7,413,204; 7,487,986. Other US and Worldwide patents pending. Made in USA © 2009 AMP Research Three-year limited warranty. Professional installation is recommended. Nationally Distributed by Bestop. www.amp-research.com 1/9 IM2996 rev 7.14.09 AMP RESEARCH POWER STEP – FORD F150 INSTALLATION GUIDE Attaching motor to linkage assembly The motors must be attached to the linkage assemblies before continuing the installation process. EXPLODED VIEW 19-03129-11 Motor 19-03179-90 Socket cap screw 19-03133-90 Washer 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 T30 Torx. Tighten screws to 80 in-lbs (9N-m). Do not over torque. www.amp-research.com 2/9 IM2996 rev 7.14.09 AMP RESEARCH POWER STEP – FORD F150 A C 1 x2 D (A) 19-03225-11 End cap left (x1) (B) 19-03225-12 End cap right (x1) (C) 19-02663-90 T-nut insert (x2) (D) 19-03236-90 Socket cap screw (x2) (E) 19-03237-90 Nut plate (x2) B 20-03314-XX Running board assembly 3 2 x2 10-03006-11 Motor linkage assembly x2 10-03007-11 Idler linkage assembly 4 19-03694-90 Wire harness www.amp-research.com 5 6 19-03297-98 Controller 3/9 E x4 19-03354-90 Posi-Tap™ (Red/Grey) IM2996 rev 7.14.09 AMP RESEARCH POWER STEP – FORD F150 PARTS LIST AND HARDWARE IDENTIFICATION 7 x8 19-02487-90 Hex bolt 11 x8 19-02488-90 U-nut 8 x8 9 12 13 x16 16-03014-90 Washer Black 15 14 x25 19-02805-90 Cable Ties 7” www.amp-research.com x8 19-02802-90 Socket cap screw 19-02849-90 Hex Bolt 19-03699-90 Grommet x2 19-03339-90 Cable Ties 11” 4/9 IM2996 rev 7.14.09 AMP RESEARCH POWER STEP – FORD F150 Locate mounting points; first and last set of holes on the inner sill. Motor Linkage mounts toward the rear of the truck, with the exception of the passenger side on SuperCab trucks. Mount the motor linkage in front on the passenger side of SuperCab trucks. FRO NT MOTOR ASSEMBLY IDLER ASSEMBLY 1 Mount idler assembly and motor assembly. Note: Filing of sheet metal edge may be required if the sheet metal holes are misaligned. Install J-clips and start bolts with washers installed. Torque 16 FT-LBS. (22 N·m) 12 7 12 8 11 2 3 2 Repeat linkage installation on passenger side Attach wire harness to controller (make sure connector locking tabs fully engage). Mount controller with the two 11” tie wraps to factory conduit. 4 Remove fuse from wire harness 4 5 www.amp-research.com 5/9 IM2996 rev 7.14.09 AMP RESEARCH POWER STEP – FORD F150 Route longer wire harness leg across firewall through plastic cowling to driver side. Connect red and black power leads to battery. Red lead goes to positive. Route shorter leg of harness down passenger-side wheel well. 6 7 Route longer leg of harness down along driverside wheel well and along frame of vehicle. Secure with tie wraps. Remove passenger side front kick panel and door sill plate. Roll back carpet to access hole for grommet installation. 9 8 Remove tape from 3/4” hole in floor panel above front linkage on passenger side and insert grommet. Thread all four trigger wires through grommet up into the cabin of vehicle. Seal grommet with silicone sealer. Wiring connections are located under the passenger side kick panel. 13 4 3 16 10 11 www.amp-research.com 6/9 IM2996 rev 7.14.09 AAMMPP RREESSEEAARRCCHH PPOOW WEERR SSTTEEPP –– FFOORRDD FF115500 Posi-Tap instrutions Locate this connector and unplug for improved access during wire connection Insert Tighten Insert and Tighten Strip 3/8” 13 12 Using supplied Posi-Tap connectors, connect Power Step trigger wires to like colored wires in factory wire harness as shown in step 15. SuperCrew SuperCab Regular Cab Green/Violet Green Yellow White Green/Violet White Green/Violet White Make certain each Posi-Tap is making positive contact with the copper wire inside the insulation. Reconnect factory wire harness from step 12. For SuperCab and Regular Cab connect the two extra trigger wires to the same wires listed above, Yellow connects to Green/Violet and Green connects to White. 14 15 Replace fuse. 2 4 16 17 www.amp-research.com 7/9 3 Open doors to extend drive linkage assembly (if not already extended). IM2996 rev 7.14.09 AMP RESEARCH POWER STEP – FORD F150 Attach step, sliding the mounting T-nut into position. 2 1 9 2 1 Torque 10 ft-lbs. (13.5 Nm) 9 18 19 Open doors to test. 20 1 www.amp-research.com 8/9 IM2996 rev 7.14.09 A M P R E S ELAI M R CIT H ED POW ER STEP – Y FORD F150 WARRANT AMP RESEARCH warrants product to be free from defects in material and workmanship, for terms specified below, 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 of replacement of any item found by the factory to be defective within the time period specified. 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. THE WARRANTY TIME PERIOD IS AS FOLLOWS: THREE YEARS FROM DATE OF PURCHASE. 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. OUT 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. WARNING The manufacturer strongly recommends that this product be professionally installed. Failure to carefully follow the electrical installation steps could result in severe electrical shock that could harm the installer and/or damage the vehicle. This product is designed to enhance the appearance of the vehicle. Do not rely in any way on the components of this product to contain occupants within the vehicle, or to protect against injury of death in the event of an accident. Never operate vehicle in excess of manufacturer’s specifications. WEAR SEAT BELTS AT ALL TIMES Read and follow, precisely, all installation instructions provided when installing this product. Failure to do so could place occupants of the vehicle in a potentially dangerous situation. After installing or reinstalling, check to make sure it has been properly installed. www.amp-research.com 9/9 IM2996 rev 7.14.09