Ford - F 250 - Workshop Manual - 1999 - 2007

INSTALLATION GUIDE APPLICATION LENGTH MODEL YR PART # Bestop 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”) (72”) (72”) 1999–2007 1999–2007 1999–2007 2000–2005 10-02513-24 10-02513-25 10-02513-26 10-02513-26 75102-01 75103-01 75104-01 75104-01 *NOTE: Minor modification required for Ford Excursion. See Page 2, items 2 and 3. INSTALLATION TIME 3:00 hrs SKILL LEVEL 1 2 3 4 4= Experienced TOOLS REQUIRED 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, 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 1/11 IM2513 rev 7.15.09 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 insure our customers receive all components with full integrity, we pack the motors seperate 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 2/11 IM2513 rev 7.15.09 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION A C 1 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) x2 B 20-03314-XX Running board assembly GRIND 1/4" GRIND 1/4" EXCURSION ONLY EXCURSION ONLY 3 2 x2 10-02624-14 Motor linkage assembly x2 10-02641-14 Idler linkage assembly 4 19-02726-91 Wire harness www.amp-research.com 6 5 19-03297-93 Controller 3/11 E x2 19-02890-90 Double-diode IM2513 rev 7.15.09 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION PARTS LIST AND HARDWARE IDENTIFICATION 7 8 x8 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 14 x8 16-03014-90 Washer (black) x25 19-02805-90 Cable tie (7”) 15 19-02992-90 Tubing (installation tool) 17 16 x2 19-02986-90 Connecting wire (red) 18 x2 19-03354-90 Posi-Tap® connector 19-02989-90 Butt connector www.amp-research.com x4 4/11 IM2513 rev 7.15.09 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION DRIVER SIDE Second and last set of holes from the front DRIVING ASSEMBLY FR ON T 1 Note: Driving 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 5/11 IM2513 rev 7.15.09 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 6/11 IM2513 rev 7.15.09 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 Adjar Wire Roll back carpet See Detail 15 www.amp-research.com 6 7/11 (See wiring guides for details and step-by-step instuctions; colors and proceedures will vary per model year) IM2513 rev 7.15.09 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION NOTE: Steps 16-25, removing driver’s door panel, only for vehicles previos to 2007. 16 17 Remove door light 18 19 Remove speaker screws (See Detail 22) 20 21 www.amp-research.com 8/11 Pull back door lining IM2513 rev 7.15.09 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 preceedures will vary per model year) 22 15 23 Thread wire through tube then remove tube 15 15 CONNECTING WIRE CONNECTING WIRE To rear wire splicing 24 25 CONNECTING WIRE 6 open leg of double diode harness TRIGGER WIRE 18 rear door ajar rear door ajar wire 26 27 www.amp-research.com 9/11 IM2513 rev 7.15.09 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 29 Plug in (both sides) Replace fuse 3 2 Open doors to extend arm (if not already extended) 4 30 31 Attach step Slide mounting T-nut into position 2 1 1 10 TORQUE 10 ft-lbs (13.5 N m) 32 33 www.amp-research.com 10/11 Open doors to test IM2513 rev 7.15.09 LIMI T E D WA R R A N T Y AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION 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. This warranty gives you specific legal rights, and you may also have other rights that vary from state to state. For further information or request for warranty work, please call toll-free 1-888-983-2206 (press 5) for Customer Service. WA R N I N G 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 11/11 IM2513 rev 7.15.09 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 four (4) additional diodes that are not included in the standard parts kit If needed, additional diodes (Part #10-02727-90) may be ordered at no charge and shipped UPS Ground by calling 1-888-983-2206. 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 1-888-983-2206 (press 5) Monday - Friday, 8:00 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.. 3-year limited warranty. Professional installation is recommended. www.amp-research.com 1/11 IM2513 rev 08.22.07 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION 07 WIRING GUIDE Ford Super Duty (2007) With remote keyless entry W 3RVL7DSŒ FRQQHFWRU 'RXEOH GLRGH KDUQHVV Driver-side wiring $ % $GGLWLRQDO FRQQHFWLQJ ZLUH 5HG *D & %XWW FRQQHFWRU $ % 7R 'RRU /DWFK 5HDURI7UXFN )URQW RI7UXFN %RG\ RI7UXFN <%ON <%ON &RQQHFWLQJ :LUH &RQQHFWLQJ :LUH /*< /*< )URQW 6LOO3ODWH '5,9(56,'(:,5,1* )URQW 'RRU3DQHO 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. Passenger-side wiring & 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. 3U%ON &RQQHFWLQJ :LUH 3N/% *\5 5HDU RI 7UXFN 3$66(1*(56,'(:,5,1* )URQW RI 7UXFN & )URQW 6LOO 3ODWH 3DVVHQJHU6LGH 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 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. 1RWHV  $OORIWKHVLJQDOZLUHVZHWDSLQWRZLOOEH*D'RQRWWDSLQWRDQ\WKLQJZLWKDWKLFNHUJDJHWKDQWKLV  2FFDVVLRQDOO\WKHZLUHFRORUVGRQRWPDWFKWKHZLUHVFKHPDWLFV8QGHUWKHVHFLUFXPVWDQFHV\RXZLOOQHHGWRORFDWHWKHGRRUDMDUVLJQDOZLUHV(DFKGRRUZLOO KDYHRQHZLUHOHDGLQJRXWWRLWVODWFKDQGRQHJURXQGZLUHFRPLQJDZD\7KHJURXQGZLUHZLOOXVXDOO\EHVROLGEODFN7KHVLJQDOZLUHZHQHHGLVWKHRWKHUZLUH  0DNHVXUH\RXVHFXUHDOOZLUHVDIWHULQVWDOO/RRVHZLUHVFDQEHGDPDJHGDQGPD\FDXVHDIDLOXUHLQWKH3RZHUVWHS VIXQFWLRQ www.amp-research.com 2/11 IM2513 rev 08.22.07 AMP RESEARCH POWER STEP – FORD SUPER DUTY & EXCURSION 04 - 06 WIRING GUIDE Ford Super Duty (2004 - 2006) With remote keyless entry W 3RVL7DSŒ FRQQHFWRU 'RXEOH GLRGH KDUQHVV $ $GGLWLRQDO FRQQHFWLQJ ZLUH 5HG *D Driver-side wiring % & %XWW FRQQHFWRU $ % 7R 'RRU /DWFK 5HDURI7UXFN )URQW RI7UXFN %RG\ RI7UXFN <%ON <%ON &RQQHFWLQJ :LUH &RQQHFWLQJ :LUH /*< /*< )URQW 6LOO3ODWH '5,9(56,'(:,5,1* )URQW 'RRU3DQHO  5HPRYH IURQW GRRU SDQHO DQG ORFDWH EXQGOH RIZLUHV EHORZ DQG WR WKH OHIW RI VSHDNHU $UHD$  2SHQ EXQGOHDQG ORFDWH *D GRRUDMDU ZLUH \HOORZ ZLWK EODFN VWULSH  &DXWLRQ