Ford - F 250 Super Duty - Workshop Manual - 1999 - 2007

INSTALLATION GUIDE APPLICATION LENGTH MODEL YR PART # Ford Super Duty F-250 / F-350 Regular Cab Ford Super Duty F-250 / F-350 Super Cab Ford Super Duty F-250 / F-350 Crew Cab Ford Excursion* (48”) (60”) (79”) (79”) 1999–2007 1999–2007 1999–2007 2000–2005 75104-01A 75104-01A 75104-01A 75104-01A INSTALLATION TIME 3:00 hrs SKILL LEVEL 1 2 3 4 4= Experienced TOOLS REQUIRED q q q q q q q q q q q q q Safety goggles Measuring tape Flat blade screwdriver Phillips head screwdriver 13mm socket 8mm 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 ) AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday - Friday, 6:00 AM - 5:00 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 © 2010 AMP Research 5-year limited warranty. Professional installation is recommended. www.amp-research.com 1/12 IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION 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 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: 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 Hex Head. Tighten screws to 36 in-lbs (4N-m). Do not over torque. www.amp-research.com 2/12 IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION Note: Some Applications require modification. Application Crew Cab/Excursion Super Cab Regular Cab Cut Length 79” (No Modification Required) 60” (Trim 19”) 48” (Trim 31”) Cut dimension 1 (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) x2 20-03314-XX Running board assembly 3 2 x2 10-02624-14 Motor linkage assembly x2 10-02641-14 Idler linkage assembly 6 4 19-02726-91L Wire harness www.amp-research.com x2 19-02890-90 Double-diode 5 19-03297-93 Controller 3/12 (Not required for all applications See Wiring Guides for details) IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION PARTS LIST AND HARDWARE IDENTIFICATION 7 x8 8 x8 19-02487-90 Hex bolt 19-02485-90 Button head - M10 11 12 x8 19-02488-90 U-nut x8 19-02486-90 Washer (stainless) 9 x2 19-03339-90 Cable tie (11”) 10 x8 19-02802-90 Socket cap screw 13 x8 16-03014-90 Washer (black) 14 x25 19-02805-90 Cable tie (7”) 15 19-02992-90 Tubing (installation tool) 18 17 16 x2 19-02986-90 Connecting wire (red) 19-02989-90 Butt connector x4 19-03354-90 Posi-Tap® connector www.amp-research.com x10 20 19 x4 19-02640-90 Grommet x4 19-03302-90 LED Lamp 4/12 IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION DRIVER SIDE Linkage Mounting Location Second from last set of holes from the front Motor Assembly FR ON T 1 Note: Motor Linkage assembly mounts in the rear; idler mounts in the front. Idler Assembly 13 7 7 8 12 2 11 2 3 TORQUE 16 ft-lbs. (22 N m) 8 2 2 4 5 www.amp-research.com 5/12 IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION 5 4 9 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. 6 5 4 _ 4 7 + 8 14 14 14 4 4 9 10 www.amp-research.com 6/12 IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION Puncture grommet and thread trigger wire 14 4 14 11 Open passenger door Remove step plate 12 Remove kick plate Roll back carpet and pull trigger-wire through grommet. TRIGGER WIRE 6 wire bundle Roll back carpet See Detail 14 13 14 (See Wiring Guides for wiring details) Connecting Wire or leg of Double Diode 18 Rear Door Ajar Wire Roll back carpet See Detail 15 www.amp-research.com 6 7/12 (See wiring guides for details and step-by-step instuctions; colors and procedures will vary per model year) IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION NOTE: Steps 16-25, removing driver’s door panel, only for vehicles prior to 2007. 16 17 Remove door light 18 19 Remove speaker screws (See Step 22) 20 21 www.amp-research.com 8/12 Pull back door lining IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION Insert plastic tube Door Ajar Wire 18 Connecting Wire (See wiring guides and step-by-step instrctions; colors and precedures will vary per model year) 22 15 23 Thread wire through tube then remove tube 15 15 CONNECTING WIRE CONNECTING WIRE 24 25 CONNECTING WIRE 6 To rear door wire splicing open leg of double diode harness TRIGGER WIRE 18 rear door ajar rear door ajar wire 26 27 www.amp-research.com 9/12 IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION 2004 model shown Some previous year models require that the ORANGE and WHITE wires be reversed (See wire diagram) 4 4 3 28 Plug in (both sides) 29 Replace fuse 3 2 Open doors to extend arm (if not already extended) 4 30 31 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 27” for front LED Light and 65” for rear LED LIght. Attach step Slide mounting T-nut into position 2 1 10 TORQUE 27” 10 ft-lbs (13.5 N m) 32 65” 33 www.amp-research.com 10/12 IM75104 rev 02.02.11 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION Drill a 9/32” hole through the pinch weld at marked locations. Debur all holes. Insert grommet into drilled holes. Insert lamp wires through the grommets. (Silicone lube will help wires slip through grommets.) 19 20 34 35# 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 17 36 37 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. 38 Reinstall fuse. 39 www.amp-research.com 11/12 IM75104 rev 11.22.10 Check that all doors activate the Power Step and the LED Lights work when doors open and close. Reinstall any remaining trim panels. 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 reilluminated by closing and opening any door of vehicle. www.amp-research.com 12/12 IM75104 rev 02.02.11 WIRING GUIDE WIRING GUIDE / General instructions Posi-Tap™ installation instructions 1. Insert 2. Tighten 3. Strip 3/8” Posi-Tap™ Patents: 5,228,875; 5,695,369; 5,868,589, 2,708. Other patents pending. 4. Insert & Tighten For two or more wires twist. Diodes NOTE: 2004-2006 Ford Super Duty trucks without remote keyless plus 2001 and older Super Duty trucks with remote keyless entry require additional diodes that are not included in the standard parts kit. See specific model year Wiring Guides for quantities required for your application If needed, additional diodes . (Part # Single 19-02727-90 / Double 19-02890-90) may be ordered at no charge and shipped UPS Ground by calling 1-888-983-2204 CAUTION Handle the motor and linkage assemblies with care when installing. Dropping can damage motor. Remove fuse from wiring harness during installation. Failure to do so could result in severe electrical shock. TECH SUPPORT 1-888-983-2204 (press 2) Monday - Friday, 6:00 AM - 5:00 PM PST Designed and manufactured by AMP Research. Patent 6,830,257 / 6,641,158 / 6,834,875 / 6,938,909 / 6,942,233 / 7,007,961 Other US and worldwide patents pending.. 5-year limited warranty. Professional installation is recommended. www.amp-research.com 1/11 IM75104 rev 11.22.10 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION 07 WIRING GUIDE Ford Super Duty (2007) With remote keyless entry W Driver-side wiring 1. Remove front kick panel and locate bundle of wires leaving front door just above e-brake assembly (Area-A). Open bundle and locate 18Ga door-ajar wire (yellow with black stripe). Caution: You may find two wires with these colors; the correct wire will ground when the door is open (ohm meter will read low resistance with door open and OL (open line) with the door closed. 2. Using supplied Posi-Tap connectors, splice supplied red connecting wire into yellow with black stripe wire. 3. Route red wire down to sill plate. 4. Attach purple Power step trigger wire to blue butt connector of “double diode harness”. 5. Attach one leg of “double diode harness” to open end of red connecting wire. 6. Using supplied Posi-Tap connectors, splice remaining leg of “double diode harness” into rear door-ajar wire ( light green with yellow stripe) Caution: You may find two wires with these colors; the correct wire will ground when the door is open (ohm meter will read low resistance with door open and OL (open line) with the door closed. Passenger-side wiring 1. Remove sill plate and attach purple Power Step trigger wire to blue butt connector of “double diode harness”. 2. Open wire bundle and locate door-ajar wires ( rear: pink with light blue stripe; front: grey with red stripe. Both wires pass under front seat as shown in figure-C www.amp-research.com 3. Using supplied Posi-Tap connectors, splice the open legs of the “double diode harness” into the door-ajar wires. 4. If necessary, attach red connecting wire to “double diode harness” to extend length as needed. 2/11 IM75104 rev 8.22.07 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION 04 - 06 WIRING GUIDE Ford Super Duty (2004 - 2006) With remote keyless entry W Driver-side wiring CAUTION: You will find two wires with these colors; the correct wire will ground when the door is open (ohm meter will read low resistance with door open and OL with door closed). Passenger-side wiring www.amp-research.com 3/11 IM75104 rev 08.22.07 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION WIRING GUIDE Ford Super Duty (2004 - 2006) Without remote keyless entry SINGLE DIODES REQUIRED If diodes were not ordered with kit, they can be ordered at no charge and shipped UPS Ground by calling 1-888-983-2206 04 - 06 W/O Driver-side wiring Passenger-side wiring www.amp-research.com 4/11 IM75104 rev 08.22.07 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION NOTE: The two wires to each of the motor plugs (orange and white) must be reversed. WIRING GUIDE Ford Super Duty (2002 - 2003) With remote keyless entry 02 - 03 W Driver-side wiring DRIVER SIDE WIRING 1. Remove front door panel and locate bundle of wires below and to the left of speaker (Area-A). Open bundle and locate 18 Ga door-ajar wire (yellow with black stripe). CAUTION: You may find two wires with these colors; use wire that leads out to door latch. 2. Using supplied Posi-Tap™ connectors, splice supplied red connecting wire into yellow with black stripe wire. 3. Route red wire back into cab of vehicle and back toward rear sill plate. 4. Remove rear sill plate, open wire bundle and locate 18 Ga. black wire. Cut this wire and attach the end of the connecting wire from step-3 as shown in figure-C. 5. Using supplied Posi-Tap™ connectors, splice purple Power Step trigger wire into rear door-ajar wire (light green with yellow stripe), located under front sill plate. CAUTION: You will find two wires with these colors; the correct wire will ground when the door is open (ohm meter will read low resistance with door open and OL with door closed). Passenger-side wiring PASSENGER SIDE WIRING 1. Remove passenger side front sill plate, open wire bundle and locate rear door-ajar wire (pink with light bllue stripe). This wire will be located rear of junction where wires route under from passenger seat. 2. Using supplied Posi-Tap™ connectors, splice purple Power Step trigger wire into pink with light blue stripe wire. www.amp-research.com 3. Cut the black 18 Ga wire found in wire bundle, forward of junction where wires route under front seat. 4. Using supplied Posi-Tap™ connectors, splice rear section of cut black wire into fron door-ajar wire (grey with red stripe) as shown above. 5. Tape off the remaining open end of the black wire (front section). 5/11 IM75104 rev 08.22.07 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION NOTE: The two wires to each of the motor plugs (orange and white) must be reversed. WIRING GUIDE Ford Super Duty (2002 - 2003) Without remote keyless entry 02 - 03 W/O Driver-side wiring Passenger-side wiring www.amp-research.com 6/11 IM75104 rev 08.22.07 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION WIRING GUIDE Ford Super Duty (2001) With remote keyless entry SINGLE DIODES REQUIRED If diodes were not ordered with kit, they can be ordered at no charge and shipped UPS Ground by calling 1-888-983-2206 99 - 01 W NOTE: On 2001 and older models the factory harness does not split and cross over from passenger to driver side under front seats, but does on all other model years. Driver-side wiring locate 18Ga door-ajar wire (black with yellow stripe). red connecting wire into black with yellow stripe wire. Passenger Side Passenger-side wiring www.amp-research.com 7/11 IM75104 rev 08.22.07 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION WIRING GUIDE Ford Super Duty (2004 - 2006) Regular Cab & Extended Cab With remote keyless entry Driver-side wiring 04 - 06 W Passenger Side Passenger-side wiring www.amp-research.com 8/11 IM75104 rev 08.22.07 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION WIRING GUIDE Ford Super Duty (2002 - 2003) Regular Cab & Extended Cab With remote keyless entry 02 - 03 W NOTE: The two wires to each of the motor plugs (orange and white) must be reversed. Driver-side wiring Passenger-side wiring www.amp-research.com 9/11 IM75104 rev 08.22.07 Congratulations on the purchase of your AMP Research Power Step Here’s what you should know... OPERATION The AMP Research Power Step automatically deploys when at least one door opens and automatically retracts under your vehicle when both front and rear doors close. If resistance or blockage is encountered while the Power Step is in motion, the drive system is designed to automatically stop. To reset, simply open or close the vehicle door and the Power Step will resume normal operation. MAINTENANCE TIPS The stepping surface and drive mechanism can be washed with mild soap and water using a soft brush or sponge to dislodge any mud, dirt or accumulated road grime. Rinse with fresh water. To prevent slipping, avoid applying waxes, lubricants or protectants like Armor All® to the step surface. When washing your vehicle, the Power Steps can be set to remain deployed with the doors closed for easy cleanning. Do this... 1 With the Power Step deployed, press and hold the board down with your foot. 2 Close the door while continuing to press down the board. (This will not harm motor.) 3 To reset the Power Step, simply open and close the door. (Repeat for both sides of vehicle.) CAUTION! BE SURE TO KEEP HANDS AWAY WHEN THE POWER STEP IS IN MOTION. amp-research.com L IMI T ED WARRAN T Y 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. All remedies under this warranty are limited to the repair or 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: 5-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. 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 WARNI NG 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.