vehicle application installation instructions • ford super

Installation Instructions

INSTALLATION TIME SKILL LEVEL

4 Hours 4 - Diffi cult

TOOLS

Vehicle Application

Automatic Retracting Running Board

8 mm,13 mm

5 mm

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PowerBoard

• Ford Super Duty F-250/350/450 Crew Cab 1999 – 2007 Part Number: 75104-15

Due to Ford factory wiring changes, some 2002-2003 models require the two wires going to each motor plug to be reversed for the boards to operate properly

when using the supplied controller. As a result the lights will not work correctly. Do not install light kit at this time. Call (800) 845-3567 to get a different controller (part number 473.30) that will operate the lights correctly.

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PowerBoard – Installation Instructions

Rev. N 1011 75104 pg. 2

Parts List and Hardware Identifi cation

Wiring Harness, Part Number 473.10, Qty - 1

7" Cable Ties, Part Number 460.99, Qty - 25

Running Board Assembly, Qty - 2 79" - Part Number 460.87

Left End Cap, Part Number 460.83, Qty - 1

Right End Cap, Part Number 460.82, Qty - 1

T-Nut Insert, Part Number 460.84, Qty - 2

M6 Nut Plate, Part Number 460.86, Qty - 2

M6-1.0 x 10mm Socket Cap Screw, Part Number 460.85, Qty - 2

Idler Linkage, Part Number 473.07, Qty - 2

Motor Linkage, Part Number 473.08, Qty - 2

Controller, Part Number 460.91, Qty - 1

11" Cable Ties, Part Number 470.02, Qty - 2

M10-1.75 x 25 Socket Cap Screw, Part Number 473.19, Qty - 8

M8 Washer, Part Number 470.05, Qty - 8

Posi-Tap, Part Number 470.03, Qty - 4

M8 U-Nut, Part Number 460.98, Qty - 8

10mm Washer, Part Number 473.20, Qty - 8


M8-1.25 x 30 Hex Bolt, Part Number 473.18, Qty - 8

Light, Part Number 470.15, Qty - 4

Single Diode, Part Number 473.26, Qty - 3

Installation Tube, Part Number 470.01, Qty - 1

Butt Connector, Part Number 473.27, Qty - 6


Motor, Part Number 489.39, Qty - 2


Rev. N 1011 75104 pg. 3

Install M8 U-Nuts Install Linkages

Connect the Wire Harness to the Controller. Make sure that the locking tabs on the connectors are fully engaged.

Loop the two (2) 11" Cable Ties through the holes in the side of the engine compartment. Slide the Controller into the loops and tighten them.

Connect Wire Harness to Controller

Install Controller in Vehicle

Counting from the front, locate the second (2nd) and last set of mounting holes on the inner sill on the driver’s side. Use an M8-1.25 x 30 Hex Bolt and an 8mm Washer to install an M8 U-Nut on each side of each hole. Do not tighten the bolts at this time.

View from under vehicle

Front

Rear

Driver’s Side

M8 U-Nuts

8mm Washers

M8-1.25 x 30 Hex Bolts

Motor Linkage Position

Idler Linkage Position

Install a Motor Linkage in the rear hole and an Idler Linkage in the front hole. Slip the notches in the Linkages under the bolts and washers installed in Step One. Secure the bottom of the Linkages with two M10-1.75 x 25 Button Head Screws and two 10mm Washers.

Finger tighten the fasteners at this time.

Repeat Steps One and Two on the passenger side of the vehicle.

Idler Linkage

Driver’s Side

M10-1.75 x 25 Button Head Screws

10mm Washers

Remove the fuse from the Wiring Harness.

Remove the fuse from the Wiring Harness. Failure to do so could result in severe electrical shock which could harm the installer and/or damage the vehicle.

Remove Fuse from Wiring Harness

11" Cable Ties

Controller

Wire Harness


Rev. N 1011 75104 pg. 4

Open the passenger door and remove the step plate and kick panel.

Remove Kick Panel

Puncture the grommet and thread the trigger wire through it.

Pull back the carpet and pull the trigger wires through the grommet. Seal the holes in the grommet with silicone sealant.

Route the Wire Harness legs down to the wheels wells and to the Motor Linkages. The long leg goes across the front to the driver’s side.

Use Cable Ties to secure all loose sections of the harness.

Cable Ties

Route Wire Harness

Wire Harness

Cable Ties

Connect the Controller power and ground to battery, red lead to positive and black lead to negative.

Secure Controller and Wire Harness

Wire Harness

Route Wire Harness

Grommet

Trigger Wire

Route Trigger Wire

Pull Trigger Wire through Grommet


Rev. N 1011 75104 pg. 5

Use a Posi-Tap connector to make wiring connections. See the Wiring Information for your vehicle for details and step-by-step instructions. Colors and procedures vary according to model year.

Wiring

Posi-Tap™ Instructions

Insert Tighten

Strip 3/8" Insert and Tighten

Posi-Tap

Leg of Single Diode

Use a fl at screwdriver to pry up the button panel on the driver’s side door.

Use screwdriver to remove panel

Remove Driver’s Side Door Button Panel - Prior to 2007 Only

Separate the connectors and remove the panel from the driver’s side door.

Separate Connectors

Disconnect Driver’s Side Button Panel - Prior to 2007 Only

Use a fl at screwdriver to pry out the light lens on the driver’s side door.

Remove Driver’s Side Door Light Lens - Prior to 2007 Only

Remove the upper door molding on the driver’s side door.

Remove Driver’s Side Upper Door Molding - Prior to 2007 Only


Rev. N 1011 75104 pg. 6

Remove Driver’s Speaker Screws - Prior to 2007 Only

Remove the screws that attach the speaker to the driver’s side door.

Pull back the molding on the door to access the wiring and splice a Single Diode Harness and the Connecting Wire into position according to the wiring diagram that applies to your vehicle.

Door Ajar Wire

Connecting Wire

Install Connecting Wire - Prior to 2007 Only

Locate the plastic Connecting Wire Installation Tube in the parts kit. Thread the tube into the hole in the door, through the openings in the door and into the vehicle. Then thread the Connecting Wire through the tube. Once the wire is in place, remove the tube.

Connecting Wire Installation Tube Thread Tube into

Vehicle

Connecting Wire - Thread through Tube

To the Rear Step Plate Wire

Thread Connecting Wire - Prior to 2007 Only

Open the driver door and remove the step plate and kick panel.

Remove Kick Panel

Connect the open leg of the Single Diode to the rear door ajar wire.

Connect Trigger Wire

Pull back the carpet and pull the trigger wires through the grommet. Connect to a Single Diode connector. Seal the holes in the grommet with silicone sealant.

Route Trigger Wire

Trigger Wire

Connecting Wire

Single Diode

Single Diode

Rear Door Ajar Wire


Rev. N 1011 75104 pg. 7

Reinstall the fuse in the harness.

Reinstall Fuse

Slide Motor assembly onto drive shaft and mount-ing bosses of Motor Linkage assembly. Use three (3) M6-1.0 x 30mm Socket Cap Screws to secure Motor. Plug female connector into Motor. Wrap any exposed wires from the motor with electrical tape.

Install Motor

Clean the outboard surface of the of the Linkage below the bottom mounting bolt. Peal the adhesive liner off the back of the Light and fi rmly press it 1/8" below the mounting bolt. Plug the light into the connector with the black and orange wires in the wire harness. Repeat with the other three lights. Secure lose wires with Cable Ties.

Install Lights

Motor Linkage

Motor

Wire Harness

Light

Linkage

M6-1.0 x 30mm Socket Cap Screws

M6-1.0 x 20mm Socket Head Bolts

Arm

PowerBoard

Install Running Boards



Wire Harness

Cable Ties

Secure Harness – Driver’s Side

Thread the plug end of the Wire Harness to the Motor Linkage on the Driver’s Side and make sure that it is secured with Cable Ties ties.

Mount the Steps to the linkages. Slide the mounting T-Nut into position. Install M6-1.0 x 20mm Socket Head Bolts to secure the boards. Use a 5mm Allen Wrench to tighten the bolts.

Make sure the board moves up and down freely by hand. If it binds, loosen the linkage to body attach-ment bolts and adjust the linkage position until the boards move freely. Do not tighten the bolts at this time.

Tightening the fasteners before cycling the step several times may create a

bind, causing a squeaking sound and preventing the boards from retracting completely and evenly.


Rev. N 1011 75104 pg. 8

Open the doors to make sure that the PowerBoard drops into position on each side of the vehicle.

Cycle boards several times and then fully tighten all bolts.

Test Doors and PowerBoards

Once you have confi rmed that the PowerBoard works properly reassemble the doors, if neces-sary, and reinstall the kick plates and door sills.

Reassemble Doors

Issue:• Possible cause

Boards do not operate:• Connected to incorrect vehicle wire• Wire connections not secure• Fuse burned• Diodes reversed or damaged• Factory door-ajar circuit inoperable

Board creaks or squeaks during operation:• Gear shaft wedge bolt is loose• Loosen mounting bracket and board attach-

ment screws. Adjust linkages so they are parallel to each other and the noise is gone. Tighten all fasteners.

Intermittent operation:• Wire connections not secure• Bad ground• Bad battery connection

Boards operate randomly:• Wire connections not secure• Diodes reversed or damaged• Connected to incorrect vehicle wire

Board stays down all the time and can be moved by hand:

• Gear shaft wedge screw is missing or loose

Board shakes and or shutters during operation:• Bad ground• Wire connections not secure• Bad battery connection

One or more doors operate the board and other do not:

• Wire connections not secure• Diodes reversed or damaged

Delay in board operation or boards operate after doors are shut:

• Diodes reversed or damaged

PowerBoard TroubleshootingConfirming PowerBoard is functional-black controller:

To test if the black controller (460.91), wire harness, motor and lights work, hook up to battery and touch any of the 4 door trigger wires to ground. The board for that side should go down and the lights should turn on. The board should go up and the lights should turn off when the wire is removed from ground.

Boards don’t operate correctly when connected to wires identified in instructions:

Unfortunately vehicle manufactures do not consistently keep the same wire colors in their wire harnesses. The PowerBoard trigger wires need to be connected the factory door-ajar wire that is connected to each door latch switch. The correct wire is likely in the same bundle that is identified in the instructions. If none of them work you can locate the correct wire by removing the door panel and tracing the wire bundle that leads to the door latch.

Use an ohm meter or continuity tester to find the door-ajar wire on PowerBoards with black controllers. The correct wire will go from neutral to ground when the door is opened and return to neutral when the door is shut. Connect one test lead to the negative battery terminal and probe the wires with the other lead. You can use a pin or a Posi-Tap connector to pierce the wire insulation. The correct wire will make the tester go from no continuity to complete continuity when the door opened and return to no continuity when the door is shut. You can also shut the door latch with the door open by pushing on the latch catch with a screw driver.

PowerBoard Service Tips


Rev. N 1011 75104 pg. 9

LIMITED WARRANTYWe warrant our product to be free from defects in material and workmanship, for the terms specifi ed 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 or replacement of any item or items found by the factory to be defective within the time period specifi ed. If you have a warranty claim, fi rst 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, fi re, 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 FOR ALL PowerBoards MANUFACTURED BY OUR COMPANY: THREE YEARS / 36,000 MILES 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 specifi c legal rights, and you may also have other rights which vary from state to state.

For further information or request for warranty work, please contact:Bestop Inc. Customer ServiceToll-Free: (800)845-3567Main: (303)465-1755E-mail: [email protected]: www.Bestop.com

Checking Diodes:

If a diode is faulty or installed backwards, the system will not receive necessary signal to deploy the step. Diodes transmit current in only one direction. To test, disconnect the diode from the system. The diode will have a silver stripe on one end. Connect the side of the diode without the stripe to positive twelve volts. Connect the end with the stripe to a tester and ground the tester. Current should flow through the diode in this direction. There should be no current flow when the end with the stripe is connected to positive twelve volts. The diode is bad if current flows in this direction or there is no current flow in either direction.

PowerBoard Service Tips (continued)

Linkage Component Identifi cation

Motor Gear Shaft

Motor Mounting Boss

Mounting Tab

Upper Casting

Outer Link

Inner Link

Lower Casting

Mounting Foot

Motor Linkage

Idler Linkage

Pivot Leg

PowerBoard – Wiring Instructions

Rev. N 1011 75104 Wiring pg. 10

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 (yel-low with black stripe).

CAUTION: You may fi nd two (2) 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 door closed.

2. Using supplied Posi-Tap connectors, splice a purple trigger wire into yellow with black stripe wire.

3. Use supplied Posi-Tap connectors to splice remaining purple trigger wire into rear door ajar wire (light green with yellow stripe).


Ford Super Duty (2007)with remote keyless entry

07W

1. Remove sill plate and 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.

2. Use supplied Posi-Tap connectors to splice a purple-black wire into each door ajar wire.

Notes:1. All signal wires tapped into will be 18Ga. Do not tap into anything with a thicker gauge than this.

2. Occasionally the wire colors do not match the wire schematics. Under these circumstances, you will need to locate the door ajar signal wires. Each door will have one wire leading our to its latch and one ground wire coming away. The ground wire will usually be solid black. The signal wire needed is the other wire.

3. Make sure you secure all wires after installation. Loose wires can be damaged and may cause a failure of the PowerBoard's function.

BA

Driver Side WiringPassenger Side Wiring

Front Door Panel

Front Sill Plate

To Door Latch Body of Truck

Y-BlkY-Blk

Long Purple

Front of Truck Rear of Truck

LG-YLG-Y

Sho

rt P

urpl

e

C

Front of TruckRear of Truck

Front Sill Plate

Long Purple Black Short Purple Black

PK-LB Gy-R

Posi-Tap™ Connector


Rev. N 1011 75104 Wiring pg. 11

1. Remove front door panel and locate bundle of wires below and to the left of speaker (Area A). Open bundle and locate 18Ga Door Ajar Wire (yellow with black stripe).

CAUTION: You may fi nd two (2) wires with these colors; use wire that leads out to door latch.

2. Route a purple wire through the door.

3. Using supplied Posi-Tap connectors, splice the purple wire into yellow with black stripe wire.

4. Use supplied Posi-Tap connectors to splice the remaining purple trigger wire into rear door ajar wire (light green with yellow stripe).


Ford Super Duty (2004 – 2006)with remote keyless entry

04 - 06W

1. Remove sill plate and 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.

2. Use supplied Posi-Tap connectors to splice a purple-black wire into each door ajar wire.




BA

Driver Side Wiring Passenger Side WiringFront Door Panel

Front Sill Plate


Y-BlkY-Blk

Long Purple


LG-YLG-Y

Sho

rt P

urpl

e

C


Front Sill Plate

Long Purple Black Short Purple Black

PK-LB Gy-R



Rev. N 1011 75104 Wiring pg. 12

CB

A



2. Route a purple wire through the door.


4. Use supplied Posi-Tap connectors to splice the remaining purple trigger wire into the yellow with black strips wire.


Ford Super Duty (2004 – 2006)without remote keyless entry

04 - 06W/O

1. Remove front sill plate and open wire bundle and locate rear door ajar wire (pink with light blue stripe). This wire will be located rear of the junction where the wires route under the front passenger seat.

2. Cut wire and install Single Diode harness as shown in Figure C.

3. Locate front door ajar wire (also pink with light blue stripe). This wire will be located in front of the junction where the wires route under the front passenger seat.

4. Cut wire and install Single Diode harness as shown in Figure C.

5. After both Single Diode harnesses have been installed, attach a purple-black trigger wire to each blue connector on each diode harness.




BA


Front Sill Plate


Y-BlkY-Blk

Long Purple

Front of Truck

Rear of Truck

PK-LB

Sho

rt P

urpl

e

C


Front Sill Plate

Long Purple Black

Short Purple Black

PK-LB PK-LB


Single Diode Harness


Rev. N 1011 75104 Wiring pg. 13

D

1. Cut one of the purple wires next to the wire loom conduit and save for a connecting wire.



3. Using supplied Posi-Tap connectors, splice a purple connecting wire into yellow with black stripe wire.

4. Route purple wire back into cab of vehicle and back toward rear sill plate.5. Remove rear sill plate, open wire bundle and locate 18Ga black wire. Cut this wire

and attach the end of the purple connecting wire from Step 3 as shown in Figure C.6. Use supplied Posi-Tap connectors to splice purple trigger wire into rear door ajar

wire (light green with yellow stripe) located under front sill plate.CAUTION: You may fi nd two (2) 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 door closed.

Ford Super Duty (2002 – 2003)with remote keyless entry

02 - 03W

1. Remove passenger side front sill plate, open wire bundle and locate door ajar wires (pink with light blue stripe). This wire will be located rear of the junction where wires route under passenger seat.

2. Use supplied Posi-Tap connectors to splice a purple-black trigger wire into door ajar wire.

3. Cut the black 18Ga wire found in wire bundle, forward of junction where wires route under front seat.

4. Use supplied Posi-Tap connectors to splice a rear section of cut black wire into front door ajar wire (grey with red stripe) as shown.

5. Tape off the remaining open end of the black wire (front section).

6. The second purple-black wire will not be used.




Due to Ford factory wiring changes, some 2002-2003 models require the two wires going to each motor plug to be reversed for the boards to operate properly when using the supplied controller. As a result

the lights will not work correctly. Do not install light kit at this time. Call (800) 845-3567 to get a different controller (part number 473.30) that will operate the lights correctly.


Front Sill Plate

Y-BlkY-Blk

Purple Connecting

Front Rear

LG-Y

Pur

ple

Trig

ger

D


Front Sill Plate

PR-Blk

PK-LBGy-R


A BC

CRear Sill Plate

LG-Y

Front Rear

Blk

Purple ConnectingPurple Connecting

Blk

Cut & Tape Off

Blk

Cut & Tape Off


Rev. N 1011 75104 Wiring pg. 14

CB

A

1. Cut one of the purple wires next to the wire loom conduit and save for a connecting wire.

2. Remove front door panel and locate bundle of wires below and to the left of speaker (Area A). Open bundle and locate 18Ga Door Ajar Wire (light green with yellow stripe).

3. Route the purple wire that is still on the harness through the door. Using the sup-plied Posi-Tap connector, splice the purple trigger wire into light green with yellow stripe wire.

4. Locate black 18Ga wire in the same area (Area A). Cut wire and attach the purple connecting wire to one end as shown. Tape off the open end as shown.

5. Route the purple wire that is still in the harness through the door. Use the supplied Posi-Tap™ connector to splice the purple trigger wire into the light green with yellow stripe wire

6. Open wire bundle under front sill plate and locate the door ajar wire (black with white stripe).

7. Cut this wire and connect the other end of the purple connecting wire that comes from the black wire of Step 3 to the rear end of the wire. Tape off the open end of the cut wire as shown in Figure B.

Ford Super Duty (2002 – 2003)without remote keyless entry

02 - 03W/O

1. Remove passenger side front sill plate, open wire bundle and locate front door ajar wire (pink with light blue stripe). This wire will be located forward of the junc-tion where wires route under passenger seat.

2. Use supplied Posi-Tap connectors to splice a purple-black trigger wire into door ajar wire (pink with light blue stripe).

3. Locate the ground wire for the rear door ajar wire (black with a white stripe). This wire will be located to rear of the junction where the wires route under the pas-senger front seat.

4. Cut this wire (black with white stripe) and ground the one end to the vehicle's ground as shown. We suggest using ring terminal and sheet metal screw or extend wire to a grounded terminal. Tape off the open end.

6. The second purple-black wire will not be used.




Due to Ford factory wiring changes, some 2002-2003 models require the two wires going to each motor plug to be reversed for the boards to operate properly when using the supplied controller. As a result

the lights will not work correctly. Do not install light kit at this time. Call (800) 845-3567 to get a different controller (part number 473.30) that will operate the lights correctly.


Front Sill Plate

Long Purple Wire

Front Rear

Blk-W

C


Front Sill Plate

PR-Blk

PK-LB


BA

Blk-W

Cut & Tape Off

To Door Latch

LG-Y LG-Y

Purple Connecting to Blk Wire

Cut & Tape Off

Purple Connecting to Blk Wire

Cut & Ground to Floor


Rev. N 1011 75104 Wiring pg. 15

D

C



2. Route a purple trigger wire through the door.


4. Remove the front sill plate. Open wire bundle and locate rear door ajar wire (black with white stripe).

5. Cut wire and install Single Diode harness as shown in Figure B.

6. Connect blue connector of Single Diode harness to purple trigger wire that was pulled through the fl oor.

Ford Super Duty (2001)with remote keyless entry

99 - 01W

1. Cut one of the purple wires with black stripe next to the wire loom conduit and save for use as a connecting wire.

2. Use supplied Posi-Tap™ connector to splice the remaining purple trigger wire into black with pink stripe wire.

3. Route the purple-black wire back into cab of vehicle and down to sill plate.

4. Remove step plate (Area D), open wire bundle and locate rear door ajar wire (black with a white stripe).

5. Cut wire and install a Single Diode harness oriented as in Figure C.

6. Attach connecting wire from Step 3 and purple-black signal wire from Power-Board harness to Single Diode harness as shown in Figure D.




BA


Front Sill Plate


Y-BlkY-Blk

Long Purple


Blk-W

Sho

rt P

urpl

e

DC


Front Sill Plate

Purple Black Connecting

Purple Black

Blk-W


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.

Single Diode Harness

Blk-W

To Door LatchBody of Truck

Blk-PBlk-P

Front Door Panel

Blk-W


Rev. N 1011 75104 Wiring pg. 16

B



2. Route a purple trigger wire through the door.


4. The other purple wire will not be used.

Ford Super Duty (2004 – 2006) Regular Cab & Extended Cab with remote keyless entry

04 - 06W

1. Remove passenger side sill plate. Open wire bundle and locate door ajar wire (grey with red stripe).

2. Use supplied Posi-Tap connectors to splice a purple-black trigger wire into grey with red stripe wire.

3. The other purple-black wire will not be used.




Driver Side Wiring Passenger Side Wiring

Front Door Panel

Y-BlkY-Blk

Purple Connecting


Front Sill Plate

Purple Black

Gy-R


AB

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