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How to Install Amp Research PowerStep XL Running Boards on your Dodge Ram
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
- Weather proof caulking (silicone sealer)
- Silicone spray
Shop Parts in this Guide
INSTALLATION GUIDE
Attaching motor to Linkage assembly.
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.
HARDWARE MOUNTING OVERVIEW (passenger side shown)
1. Locate forward most and rearward most mounting provisions on inner sill of truck. Remove tape from sill drain hole at both mounting points.
2. Set Reinforcement Plate in place and locate with rivet nuts. Drill hole using an 1/8” drill bit. After drilling apply paint to prevent rusting
3. Once hole is drilled insert a piece of string or wire through hole in Reinforcement Plate. Set plate into position.
4. Set rivet nuts into place for alignment. Insert pop rivet through hole in plate and secure in place. Once pop rivet is installed remove string or wire from Reinforcement Plate. NOTE: Verify plate is pulled flush to the body before securing pop rivet.
5. Assemble Hex Bolt (lubricated with soapy water), Washer, Rivet Tool, and Rivet Nut together as shown and place into hex cutouts in sill. An extra Hex Bolt and M8 Washer is supplied to install rivet nuts.
6. With Rivet Nut Tool held in place with 19mm wrench, tighten Hex Bolt until Rivet Nut deforms and secures itself to the sheet metal (11 0 in-Lbs. or 4 turns). Remove Hex Bolt and Rivet Nut Tool. Repeat for each of the four mentioned mounting locations.
7. Once rivet nuts are in place use a screwdriver to push back tab in hole to avoid interference with linkage mount.
NOTE: Models with holes in Pinch Weld Skip to Step #12
8. Fold both the passenger and driver side templates in the proper direction noted on the template. Thread in hex bolts and slide slots in template up to bolts. Next use tape and apply tape on all surfaces on template that is labeled “Tape”. Start at Hex bolts and make sure template is flat on each surface. Work your way down and out.
9. Mark appropriate holes as indicated with a center punch. Front linkage marked “Front” and Rear linkage marked “Rear”.
10. Using a marker draw cross hatch to verify bit does not walk while drilling.
11. Pre drill hole using an 1/8” drill bit. Next drill holes to 9/32”. Debur all surfaces. NOTE: Filing of hole may be required if drill bit wandered. After drilling apply paint to prevent rusting.
12. Install Brackets onto vehicle. On Passenger side install Rear Rail Mounting Bracket (35) and Front Linkage Mounting Bracket (33) using the Hardware provided. 4 Conical washer bolts (9), 4 Button Head Torx (19), washers (20) and Flange Nuts (21). Once bolts are tightened up to vehicle torque Conical washer bolts (9) to 16 ft-lbs and Button head Torx to 6ft-lbs.
13. Insert and position Carriage bolts (16) into slot on rail (4). Insert from either end of rail. Using Flange Nuts (17) provided assemble rail to Brackets onto the rail. Next install Flange Bolt (14) and Flange Nut (17) onto bracket tab. Driver side shown. Dimensions shown are for reference. Torque flange nuts to 16ft-lbs.
14. Thread supplied bolts 2x (9) into Front Drive Linkage. Repeat step for Rear Idler Linkage. Do not tighten.
15. Install provided spacer (22) and M6 bolt (13) into upper mount as shown on both the Drive and Idler linkages. Do not tighten.
16. Slide mounting T-nut into position, Center board in rail pocket. Tighten fasteners to 10 ft-lbs.
17. Using a 13mm socket Torque linkage bolts 4x (9) from step 3 to 16 ft-lbs. Next use a 10mm socket, torque linkage spacer bolt 2x (13) from step 6 to 8 ft-lbs. Once linkages are tight cycle board to verify steps deploy under own weight.
18. Once linkages are tightened to the bracket tighten bracket tab Flange bolt (14) and Nut (10). Torque to 16 ft-Lbs.
19. Attach motor to linkage. Using a 4mm hex Torque to 36 in-Lbs.
20. Prepare large tie-wraps for mounting Power Step Controller. Loosely loop tie-wraps around large bundle of wires behind battery in engine compartment.
21. Insert controller into tie-wrap loops and cinch down securely. The tie-wraps should cinch down into channels on controller surface.
22. Remove fuse from Power Step Wire Harness.
23. Connect power leads from Controller, Red to positive battery terminal and Black to the vehicle body ground as shown.
24. Splice Power Step trigger wires into the Door Ajar wires with provided Posi-TapTM splicers. The Power Step trigger wires color coordinate with the factory Door Ajar wires. Follow the steps below to correctly splice wires.
25. Route the trigger wires of Power Step Harness (Purple wires) down toward the fuse box located in front of the battery.
26. Remove fuse box lid and fuse box power lead with 13mm wrench. While depressing release tabs, lift fuse box to view bottom side.
27. Locate and remove Black Connector with Gray latch on bottom side of fuse box (labeled “G” where connected to fuse box).
28. Locate the vehicle’s Door Ajar Switch wires on the removed connector as indicated in chart and diagram below according to vehicle model year.
29. Splice Power Step trigger wires into the Door Ajar wires with provided Posi-TapTM splicers. The Power Step trigger wires color coordinate with the factory Door Ajar wires. Follow the steps below to correctly splice wires.
30. With Posi-Taps securely in place, carefully replace connector and drop wire bundles and fuse box back into place. Reattach fuse box power lead that was removed in previous step.
31. Route the two Wire Harness legs down over the wheel wells toward Motor Linkages, long leg across to the passenger side. Secure harness with tie wraps.
32. On driver side, run Wire Harness leg down and along underside of the vehicle floor and frame to front Drive Linkage. Connect harness to motor and secure harness with tie wraps. Route remainder of wire harness towards rear linkage assembly for LED lights
33. On Passenger Side, run Wire Harness leg down and along underside of the vehicle floor and frame to front Drive Linkage. Connect harness to motor and secure harness with tie wraps. Route remainder of wire harness towards rear linkage assembly for LED lights
34. Affix LED lamp (20) to LED Bracket (22) as shown.
35. Affix LED light bracket assembly to rail. Mount front light rearward of front linkage and mount rear light just forward of rear linkage.
36. Using supplied butt connectors, 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 cable ties. Pull lamp wires upward to avoid any wire snagging.
Reinstall Fuse and 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 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.
