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PERFORMANCE SPECIFICATION
FOR AUTOMOTIVE ELECTRICAL CONNECTOR
SYSTEMS

SAE/USCAR-2 REVISION 7
February 2020
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ISBN: 978-1-4686-0163-3
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SAE/USCAR-2 REVISION 7 Issued

Revised
1997-08
2020-02

PERFORMANCE SPECIFICATION
FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS

Notice about interim revisions: Updates may be made as “interim revisions.” Interim revisions are available at:
https://ewcap.uscarteams.org/revisions.html.

TABLE OF CONTENTS

1. SCOPE ....................................................................................................................................................... 4

2. TEST SEQUENCE ..................................................................................................................................... 4

3. REFERENCED DOCUMENTS .................................................................................................................. 4

3.1 Document Hierarchy .................................................................................................................................. 4
3.2 Part Drawing .............................................................................................................................................. 5
3.3 Product Design Specification ..................................................................................................................... 5
3.4 Test Request/Order.................................................................................................................................... 5
3.4.1 Samples, Test Type, and Special Tests .................................................................................................... 5
3.4.2 Test Request/Order Instructions ................................................................................................................ 5
3.4.3 Performance and Durability Test Instructions ............................................................................................ 5
3.5 Documents Mentioned in This Specification .............................................................................................. 5

4. GENERAL REQUIREMENTS .................................................................................................................... 6

4.1 Record Retention ....................................................................................................................................... 6
4.2 Sample Documentation .............................................................................................................................. 6
4.3 Sample Size ............................................................................................................................................... 6
4.4 Test Conditions and Tolerances ................................................................................................................ 6
4.5 Equipment .................................................................................................................................................. 7
4.6 Measurement Resolution ........................................................................................................................... 7
4.7 Test Repeatability and Calibration ............................................................................................................. 7
4.8 Conformance Determination ...................................................................................................................... 7
4.9 Disposition of Samples............................................................................................................................... 8
4.10 Part Endurance .......................................................................................................................................... 8

5. TEST and ACCEPTANCE REQUIREMENTS ........................................................................................... 8

5.1 General....................................................................................................................................................... 8
5.1.1 Performance Requirements ....................................................................................................................... 8
5.1.2 Dimensional Characteristics ...................................................................................................................... 8
5.1.3 Material Characteristics.............................................................................................................................. 8
5.1.4 Classifications ............................................................................................................................................ 8
5.1.5 Testing Headers and Direct Connect Components ................................................................................. 10
5.1.6 Terminal Sample Preparation .................................................................................................................. 11
5.1.7 Connector and/or Terminal Cycling ......................................................................................................... 11
5.1.8 Visual Inspection ...................................................................................................................................... 11
5.1.9 Circuit Continuity Monitoring .................................................................................................................... 12
5.1.10 Mat Seal Sample Preparation .................................................................................................................. 14
5.2 Terminal Mechanical Tests ...................................................................................................................... 15
5.2.1 Terminal to Terminal Engage/Disengage Force ...................................................................................... 15
5.2.2 Terminal Bend Resistance ....................................................................................................................... 16
__________________________________________________________________________________________________________________________________________
The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the SAE International (SAE) nor the United
States Council for Automotive Research (USCAR) certifies the compliance of any products with the requirements of nor makes any representations as to the accuracy of the
contents of this document nor to its applicability for purpose. It is the sole responsibility of the user of this document to determine whether or not it is applicable for their purposes.
Copyright © 2020 USCAR Printed in U.S.A.
All rights reserved.
QUESTIONS REGARDING THIS DOCUMENT: (248) 273-2470 FAX (248) 273-2494
TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790
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5.3 Terminal - Electrical Tests........................................................................................................................ 18

5.3.1 Dry Circuit Resistance.............................................................................................................................. 18
5.3.2 Voltage Drop ............................................................................................................................................ 20
5.3.3 Maximum Test Current Capability ............................................................................................................ 22
5.3.4 Current Cycling ........................................................................................................................................ 25
5.4 Connector - Mechanical Tests ................................................................................................................. 27
5.4.1 Terminal - Connector Insertion/Retention and Forward Stop Force ........................................................ 27
5.4.2 Connector-Connector Mating/Unmating/Retention/Lock Deflection Forces (Non-Assist) ....................... 30
5.4.3 Connector to Connector Mate/Unmate Forces (Mechanical Assist) ........................................................ 33
5.4.4 Polarization Feature Effectiveness .......................................................................................................... 36
5.4.5 Miscellaneous Component Engage/Disengage Force ............................................................................. 37
5.4.6 Vibration/Mechanical Shock ..................................................................................................................... 41
5.4.7 Connector-to-Connector Audible Click ..................................................................................................... 47
5.4.8 Connector Drop Test ................................................................................................................................ 47
5.4.9 Cavity Damage Susceptibility .................................................................................................................. 48
5.4.10 Terminal/Cavity Polarization Test ............................................................................................................ 49
5.4.11 Connector Mounting Feature Mechanical Strength ................................................................................. 50
5.4.12 Mechanical Assist Integrity (Connectors with Mechanical Assist Only) ................................................... 52
5.4.13 Connector Seal Retention - Unmated Connector .................................................................................... 53
5.4.14 Connector Seal Retention - Mated Connector ......................................................................................... 54
5.4.15 Airbag Inflator Connector Self-Rejection Assessment ............................................................................. 55
5.5 Connector - Electrical Tests ..................................................................................................................... 57
5.5.1 Insulation Resistance ............................................................................................................................... 57
5.6 Connector Environmental Tests ............................................................................................................... 58
5.6.1 Thermal Shock ......................................................................................................................................... 58
5.6.2 Temperature/Humidity Cycling ................................................................................................................. 58
5.6.3 High Temperature Exposure .................................................................................................................... 59
5.6.4 Fluid Resistance ....................................................................................................................................... 60
5.6.5 Submersion .............................................................................................................................................. 61
5.6.6 Pressure/Vacuum Leak ............................................................................................................................ 62
5.6.7 High Pressure Spray ................................................................................................................................ 64
5.7 Tests for Headers ..................................................................................................................................... 66
5.7.1 Header Pin Retention ............................................................................................................................... 66
5.8 Severe Duty Tests .................................................................................................................................... 67
5.9 Test Sequence ......................................................................................................................................... 67
5.9.1 General Notes on Test Sequence ............................................................................................................ 67
5.9.2 Test Sequence Chart ............................................................................................................................... 68
5.9.3 Terminal Mechanical Test Sequence ....................................................................................................... 68
5.9.4 Terminal Electrical Test Sequence .......................................................................................................... 68
5.9.5 Connector System Mechanical Test Sequence ....................................................................................... 68
5.9.6 Connector System Electrical Test Sequence .......................................................................................... 70
5.9.7 Sealed Connector System Environmental Test Sequence ...................................................................... 71
5.9.8 Unsealed Connection System Environmental Test Sequence ................................................................ 72
5.9.9 Stand-Alone Sealing Performance Test Sequence ................................................................................. 72
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APPENDIX A DEFINITIONS .......................................................................................................................................... 73

APPENDIX B ABBREVIATIONS USED ......................................................................................................................... 77

APPENDIX C TESTS FOR MOVED TOOLS, ADDITIONAL TOOLS, AND MATERIAL CHANGES ............................. 78

APPENDIX D TESTS FOR NEW TERMINAL, CONNECTOR, AND SEAL DESIGNS .................................................. 80

APPENDIX E SOURCE LIST FOR AUTOMOTIVE FLUIDS USED IN TESTING ......................................................... 82

APPENDIX F DESIGN NOTES - TEMPERATURE AND CURRENT RATING ............................................................. 83

APPENDIX G REVISIONS .............................................................................................................................................. 84

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1. SCOPE

Procedures included within this specification are intended to cover performance testing at all phases of development,
production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection
systems in low voltage (0 to 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for
In-Line, Header, and Device Connector systems. They are not applicable to Edge Board connector systems, twist lock
connector systems, >20 VAC or DC, or to eyelet terminals.

No electrical connector, terminal, or related component may be represented as having met USCAR/EWCAP specifications
unless conformance to all applicable requirements of this specification have been verified and documented. All required
verification and documentation must be done by the supplier of the part or parts. If testing is performed by another source,
it does not relieve the primary supplier of responsibility for documentation (DVP&R) of all test results and for verification that
all samples tested met all applicable Acceptance Criteria. See 4.3.

NOTICE: If the products tested to this specification are or may be subjected to conditions beyond those described in this
document, they must pass special tests simulating the actual conditions to be encountered before they can be
considered acceptable for actual vehicle application. The Authorized Person is the final authority as to what tests
are to be performed on his or her parts and for what purpose these tests are required. He or she is also the final
authority for resolving any questions related to testing to this specification and to authorizing any variance (with
supporting data) to the equipment or procedures contained in this specification. Any such deviation must be
documented and included in the final test report. Guidance as to the recommended tests for selected purposes
is given in the charts in Appendices C and D.

2. TEST SEQUENCE

See Appendices C and D for required tests and 5.9.2 for test procedures. The tests in each section must be performed in
the order given unless otherwise specified in the test request/order. Construction details for selected test fixtures and
equipment are provided in this specification.

A glossary of terms is provided in Appendix B. Terms defined in the definitions or glossary are capitalized (i.e., room
temperature, steady state, PLR, etc.). A list of definitions is provided in Appendix A. For the purposes of this specification,
there are only two types of electrical connectors: sealed and unsealed.

3. REFERENCED DOCUMENTS

3.1 Document Hierarchy

In the event there is a conflict between performance specifications, part drawings, and other related standards or
specifications, the OEM must reconcile the differences. Any variance for any reason where the USCAR-2 procedure or
criteria is not used must be noted any place where a reference is made to the connector being USCAR-2 compliant.
Requirements that typically have priority over conflicting USCAR specifications at North American OEMs are listed below
for reference only:

1. Applicable FMVSS or other state and federal requirements

2. OEM-released Applicable part drawing(s)

3. OEM-released product design specification(s)

How to identify a connector as being USCAR-2 compliant:

Connector makers are encouraged to identify when a connector has passed USCAR testing. The following wording is to be
used when identifying USCAR compliance: “Connector passes performance requirements of USCAR-2 revision __.
Exceptions to documented USCAR tests are: (list if applicable).” Connector systems that have met the requirements of
previous revision levels of USCAR 2 may not meet the requirements of later levels. These components are compliant to the
prevailing revision at the time of release of component part. To claim compliance to a newer revision level requires testing
and acceptance to the revised version of all changed requirements.
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3.2 Part Drawing

The part drawing for each connection system component should contain or reference:

• Dimensional requirements (which must be in GD&T format).

• Performance requirements.

• Component part number.

• Reference to applicable portions of this specification.

• The quantity and part number of terminals used.

• The typical mating connector.

• Maximum permissible Temperature Sealing, Vibration, and Ergonomic class (per 5.1.4) for which the part is intended
or has been successfully tested.

3.3 Product Design Specification

The product design specification may or may not be an integral part of the part drawing. Instructions must be included in
the product design specification for any special tests required for the associated part and for any exceptions or modifications
to the general specifications and requirements in this document.

3.4 Test Request/Order

3.4.1 Samples, Test Type, and Special Tests

The laboratory test request/order shall provide location and documentation of test samples, identify the type of test to be
performed (development, validation, special purpose, etc.) and describe any special tests that are not a part of this
specification. Any required revisions to, or deviations from any tests in this specification must include detailed instructions
for each change.

3.4.2 Test Request/Order Instructions

Instructions must be included in the test request/order concerning applicable tests and the order in which the tests are to
be performed if different than outlined by this specification.

3.4.3 Performance and Durability Test Instructions

Instructions must be given in the test request/order concerning limits for performance and durability tests, including definition
of the conditions under which those limits apply, if they are different than outlined in this specification.

3.5 Documents Mentioned in This Specification

• SAE/USCAR-21 Performance Specification for Cable-to-Terminal Electrical Crimps

• SAE/USCAR-25 Electrical Connector Assembly Ergonomic Design Criteria

• AIAG MSA-4 Measurement Systems Analysis Reference Manual

• ISO TS16949 Automotive Quality Management Standard

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4. GENERAL REQUIREMENTS

4.1 Record Retention

The supplier shall maintain a central file for the storage of laboratory reports and calibration records. Such record storage
must be in accordance with established ISO TS16949 and AIAG policies and practices.

4.2 Sample Documentation

All test samples shall be identified in accordance with the requirements of ISO TS16949 and the AIAG PPAP.

4.3 Sample Size

Minimum sample sizes are given for each test in this specification. A greater number of samples may be required by the
test request/order. However, no part or device may be represented as having met this specification unless the minimum
sample size has been tested and all samples of the group tested have met the applicable Acceptance Criteria for that test.
It is never permissible to test a larger group, then select the minimum sample size from among those that passed and
represent that this specification has been met.

4.4 Test Conditions and Tolerances

1. Default Tolerances, expressed as a percentage of the nominal value unless otherwise indicated:

TABLE 4.4: TOLERANCES AND TEST CONDITIONS

Temperature ±3 °C
Voltage ±5%
Current ±5%
Resistance ±5%
Length ±5%
Time ±5%
Force ±5%
Frequency ±5%
Flow Rate ±5%
Sound ±5%
Speed ±5%
Pressure ±5%
Vacuum ±5%
Rel. Humidity ±5% (When controlled)

2. When specific test conditions are not given elsewhere in this specification, the following basic conditions apply:

Room Temperature = 23 ± 5o C
Relative Humidity = Ambient (Uncontrolled as in lab ambient conditions)
Voltage = 14.0 ± 0.1 VDC
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4.5 Equipment

Neither this list nor the list in each test section is all-inclusive. It is meant to highlight specialized equipment or devices with
particular accuracy requirements.

TABLE 4.5: EQUIPMENT

Item Description Requirements

1 DC Power Supply (Regulated) 0-20 V, 0-150 A
0-20 mV, 0-100 mA (Limits the open circuit voltage to 20 mV and
2 Micro-Ohmmeter current to 100 mA. The micro-ohmmeter must also use either offset
compensation or current reversal methods to measure resistance.)
Capable of measuring the following at an accuracy of ≤0.5% of full scale:
3 Digital Multimeter (DMM)
⇒ 0-50 VDC ⇒ 0-10 MΩ
4 Current Shunts 100 mA or as required with accuracy of ±1% of nominal
5 Millivolt Meter Capable of measuring 0-100 mV DC at 0.5% full scale
6 Thermocouples Type "J" or "T" and as required
7 Insertion/retention force Tester Capable of 1.0% accuracy, full scale
8 Data Logger As required
9 Temperature Chamber -40 to +175 °C or as required by temperature class, 0 to 95% RH
10 Vibration Controller As required
2640 N (600 pounds) sine, 2200 N (500 pounds) RMS force
11 Vibration Table
(Certification to V4 level may require larger capacity)
12 Vacuum As Required
13 Megohmmeter Accuracy <5% of full scale, capable of testing at 500 VDC
14 High Pressure Spray Equipment See 5.6.7.2
15 Decibel Meter ±1.5 dB “A” scale
16 Seal retention test Variable Speed Motor with rotating table. See 5.4.13.2.

NOTE: Use of equipment with a lesser range is acceptable for specific tests where the required range for that test can be
met. The equipment range specified does not preclude use of equipment with a larger range, but the accuracy must
remain within the specified tolerance.

4.6 Measurement Resolution

Meters and gages used in measurements of the test sample(s) shall be capable of measuring with a resolution one decimal
place better than the specified value.

4.7 Test Repeatability and Calibration

All equipment used for test sample evaluation shall be calibrated and maintained according to the applicable standards and
requirements set forth by ISO TS16949 and the AIAG publication Measurement Systems Analysis Reference Manual.
Copies of this Manual can be obtained from the AIAG. (See Appendix B for contact information.) Documentation is to be
recorded and retained in accordance with 4.1 of this specification.

4.8 Conformance Determination

Conformance shall be determined by the specified requirements of the test being conducted. All samples must satisfy the
requirements regardless of sample age, test cycles, or test temperature.
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4.9 Disposition of Samples

Should a premature non-conformance occur during a test, contact the Authorized Person to determine if the test is to be
continued to gain additional product experience or if testing is to be suspended or terminated. When contact cannot be
immediately made, the type of test shall determine the disposition of the samples. If the test order indicates that the test is
investigative in nature, continue until the requesting party or parties are available. If the test order is for sample approval or
validation, stop the test until the requesting party can be contacted. If the test must be stopped or terminated for any other
reason (safety, equipment failure, etc.) the Authorized Person must be contacted for concurrence before the test is restarted.
The test request/order should always specify desired sample disposition at the conclusion of the applicable testing.

4.10 Part Endurance

Successful completion of the requirements of this specification is intended to demonstrate that the design and construction
of the components and connector systems tested are capable of operating in their intended vehicle environment and
application for 200000 miles.

5. TEST AND ACCEPTANCE REQUIREMENTS

5.1 General

The test procedures that follow were written as steps and intended to be performed as specified in 5.9.3 to 5.9.9 as shown
in Appendices C and D.

5.1.1 Performance Requirements

Connection systems must meet all performance test requirements for the appropriate Class as listed in 5.1.4.

5.1.2 Dimensional Characteristics

Part construction shall conform to the dimensions, shape, and detail attributes specified on the latest revision of the
applicable part drawing(s).

5.1.3 Material Characteristics

Parts are intended to be in their "as furnished for vehicle assembly" condition when testing begins, unless specific
instructions as to any pre-test "conditioning" are contained in the test request/order. For example, electrical terminals
typically have residual die lubricant on them when finally assembled into a vehicle. This same condition must prevail for test
samples unless part cleaning is specified in the Test Request/Order.

All material used in each test sample shall conform to the material specifications shown on the latest revision of the
applicable part drawing(s). The material hardness specified for electrical terminals refers to the blank strip material and not
the finished product because the terminal manufacturing process can modify the hardness values.

5.1.4 Classifications

Components to be tested must be assigned a class from the table below according to the expected environment in their
intended vehicle application. Include the classifications to use in the Test Request/Order and the report of results.
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5.1.4.1 Temperature Classification

Components to be tested must be assigned a temperature class from the table below according to the expected environment
in the intended vehicle application. See Appendix F for design notes helpful to proper selection.

TABLE 5.1.4.1: COMPONENT TEMPERATURE CLASSES

Temp Class Ambient Temperature Range Typical Application

T1 is not recommended for new applications. Historically, it was the
T1 -40 to + 85 °C
temperature class for interior
T2 -40 to +100 °C Typically, suitable for use in passenger compartment
T3 -40 to +125 °C Typically, T3 is suitable for use in the engine compartment
T4 -40 to +150 °C Needed for some on-engine applications near hot components
T5 -40 to +175 °C For use as needed -- No specific applications are identified as T5

5.1.4.2 Sealing Classification

Components to be tested must be assigned a class from the table below according to the expected environment in the
intended vehicle application.

TABLE 5.1.4.2: COMPONENT SEALING CLASSES

Seal
Class Common Name Typical Application
S1 is suitable for use in passenger compartment or other dry
S1 Unsealed
areas on a vehicle such as the trunk
S2 Sealed S2 is intended for connectors exposed to water
S2.5 Sealed Against Low Pressure Spray S2.5 is intended for exposed locations at risk of direct splash
S3 is intended for exposed locations at risk of direct high-
S3 Sealed Against High Pressure Spray
pressure splash (or car wash spray)

5.1.4.3 Vibration Classification

Components to be tested must be assigned a class from the table below according to their intended vehicle applications.
See Tables 5.4.6.3A, B, C and D for shock and vibration schedules.

TABLE 5.1.4.3: COMPONENT VIBRATION CLASSES

Class Common Name Typical Application Other Requirements Met

Components on sprung portions of
V1 Chassis Profile None
vehicle not coupled to engine
Components coupled to engine with no Pass on V2 implies pass also
V2 Engine Profile
severe vibration possible for V1
Pass on V3 implies pass also
V3 Severe On-Engine Components subject to severe vibration
for V1 and V2
Used as needed to correlate to extreme Pass on V4 implies pass also
V4 Extreme Vibration
vibration areas for V1 and V2 and V3
V5 Unsprung Component Wheel-mounted components None

5.1.4.4 Ergonomic Classification

Components to be tested must be assigned an Ergonomic class from the requirements in SAE/USCAR 25. This Class
designation shall be documented in the test plan and listed on the component drawing.
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5.1.5 Testing Headers and Direct Connect Components

Cases frequently arise where only one half of a connector, usually the female half, is available and it mates directly to a
Header or to a receptacle in an electrical component or device. This presents special problems for testing. In order to
completely test the electrical connection, access must be gained to the terminals in the device or header. Great care must
be taken in these cases so as not to introduce leak paths that are not present in the vehicle application. Where this risk is
unacceptable, or making the necessary electrical connections is not feasible, the tests normally required to verify connection
integrity must be modified.

Another problem sometimes arises due to the length of the terminals or buss bars in the device or header when conducting
electrical tests. The general rule is to connect one of the millivolt test leads at the point where the Header or device terminal
attaches to the circuit board or similar point in the device. The bulk resistance of the terminal "tail" is measured and
subtracted during the connection resistance calculation.

However, if there is more than one "tail" length involved, but the bulk resistance per unit length is common, it may be more
convenient to attach the millivolt leads at a common distance from the connection to be measured.

Therefore, in situations where there is more than 50 mm from the point of contact in the connection nearest to the Header
or device to the point where the terminal "tail" or buss bar connects to the device, these two options are available. (1) Attach
the millivolt lead at a convenient common distance 30 to 50 mm from the contact to be measured. Then subtract the bulk
resistance of the selected common length when calculating the resistance of the associated Header or device connection.
(2) Measure bulk resistance of each individual Header terminal or component buss bar from the connection to be measured
to the point of millivolt lead attachment and subtract this resistance when calculating the resistance of the associated Header
or device connection. When attaching millivolt leads, take care that the heat applied does not damage plating or cause
stress relaxation in any connection component. Application of an appropriate heat sink may be advisable. See Figure 5.1.5.
Placement of the T1 lead in Figure 5.1.5 may be modified as necessary to fit the application. When using a dimension other
than the 75 mm ± 3 mm it is important to measure the resistance of a sample with an equal length of the same wire type
and use that result as the deduct value.

FIGURE 5.1.5: MILLIVOLT LEAD T1 AND T2 ATTACHMENT FOR HEADERS (TYPICAL)

It may be that the electrical component or device being connected is not itself capable- of withstanding the tests to which
the connector is usually subjected. In these cases, samples of just the connector receptacle portion of the device must be
obtained. Then the required connections for testing can be made and sealed. Leak paths in devices may need to be sealed
in order to test the integrity of mating connectors. Such modifications to the device are appropriate, but must be documented
in the test report. In any case, the Authorized Person must be consulted and must approve any deviation from the normal
tests of this performance specification.
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5.1.6 Terminal Sample Preparation

Terminals used for testing shall be crimped to requirements as defined in SAE/USCAR 21, “Performance Specification for
Cable to Terminal Electrical Crimps.” Crimp dimension physical characteristics and mechanical pull strength shall be within
tolerance as it applies to the respective terminal and wire gage. Crimp both the conductor and insulation grips unless
otherwise specified in the individual test procedures. Use the appropriate cable seal as applicable. Assemble insulation
displacement type terminals per their manufacturer’s recommended assembly criteria. When testing Header-type
connectors with mating connectors, prepare samples only for the mating female connector (see 5.1.5). Record the crimp
height and width of a representative group of samples of each terminal (except for insulation displacement type terminals)
and number samples for tracking and later identification as appropriate. Crimp information (tooling used to prepare samples,
crimp dimensions, and wire type) shall be documented in the test report.

The following note applies to wire harness fabricators: Production crimps shall be tested, validated, and approved separately
per SAE/USCAR-21 Performance Specification for Cable-to-Terminal Electrical Crimps based on wire size, stranding, and
insulation wall thickness.

5.1.7 Connector and/or Terminal Cycling

5.1.7.1 Purpose

This procedure preconditions a connection system pair or terminal system pair prior to a test sequence. Connectors may
be subjected to cycling due to in-plant and/or service repair during the life of the connector. Complete this procedure only
once when conducted as part of a test sequence as specified in 5.9 Test Sequence.

5.1.7.2 Equipment

None.

5.1.7.3 Procedure

1. Completely mate and unmate each connector or terminal pair ten times.

a. When working with terminals only, use caution to assure that mating and unmating is done along terminal
centerlines to prevent side pressure that may distort either terminal.

b. On connectors with Shorting Bars, complete the Dry Circuit measurement across the shorted contacts (connector
unmated) per 5.3.1. Record the number for later use in calculating the resistance change as part of the Dry Circuit
Test procedure.

2. Re-mate connectors or terminals for one last time in preparation for future test sequences or follow directions in the
respective procedure to follow.

5.1.7.4 Acceptance Criteria

None.

5.1.8 Visual Inspection

5.1.8.1 Purpose

This test is used to document the physical appearance of test samples. A comparison can then be made with other test
samples. Examinations in most cases can be accomplished by a person with normal or corrected vision, and normal color
sensitivity, under cool white fluorescent lighting. Photographs and/or videos are encouraged as a more complete means of
documentation. An appropriately identified untested sample from each test group must be retained for post-test physical
comparisons.
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5.1.8.2 Equipment

• Camera

• Video recorder

• Magnification apparatus (as required)

5.1.8.3 Procedure

Inspect for defects or non-functionality. Visually examine each test specimen prior to testing and/or conditioning, noting in
detail any obvious manufacturing or material defects such as cracks, tarnishing, flash, etc. When specified in the test
request/order, take photographs and/or video recordings of representative samples to be tested and keep a properly labeled
control sample.

After testing and/or conditioning, re-examine each test sample and note in detail any observable changes, such as swelling,
corrosion, discoloration, contact plating wear, physical distortions, cracks, loss of mechanical function evident, etc. Compare
the tested and/or conditioned samples to the control samples, the videos, and/or the photographs, recording any differences
in the test report. For CUTs subjected to Test Sequence Q (5.9.7), swelling of cable and seals is permissible within the limits
of that specific material specification.

5.1.8.3.1 Contact Surface Examination

At the conclusion of the Test Sequence M (5.9.6), examine terminals with the aid of 10X magnification looking for any
evidence of deterioration, cracks, deformities, excessive plating wear, etc. that could affect functionality. When visual
inspection follows Dry Circuit resistance measurement, inspect to the following (suppliers must provide criteria for plating
wear pass and fail (photographs):

• Inspect all male terminals

• Inspect all female terminals with resistance over 75% of resistance criteria

• Inspect no fewer than five female terminals

5.1.8.3.2 Sealing/Environmental Protection [Solution Intrusion]

At the conclusion of the appropriate Test Sequence as specified in 5.9.7 and 5.9.9, thoroughly dry the samples and then
disconnect each mated sample pair and perform the Visual Inspection of all inside areas and sealing surfaces. When
disconnecting the samples, use care not to allow any residual solution to enter the interior of any connector half. Careful
examination is required to detect any trace of solution intrusion.

5.1.8.4 Acceptance Criteria

The device under test must not show, any evidence of deterioration, cracks, deformities, etc. that could affect their
functionality. Additional procedure-specific criteria may be listed under each test.

5.1.9 Circuit Continuity Monitoring

5.1.9.1 Purpose

Some procedures require continuous circuit monitoring of connectors during conditioning. The purpose of circuit monitoring
is to detect intermittencies caused by micro-motion and resultant wear or build-up of non-conductive debris at the contact
interface. Use this procedure when specified in the individual test.
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5.1.9.2 Equipment

• Continuity tester (CT)

• Power supply capable of 100 mADC

5.1.9.3 Procedure

At least ten individual terminal and five connector pairs must be monitored. On connectors with up to ten cavities, all cavities
shall be monitored on the five samples. On connectors with more than ten cavities, all terminal cavities must be represented
in the five samples, with a minimum of 50 terminals monitored. Monitored terminal pairs should be distributed as evenly as
possible among the connectors tested. Distribution of monitored pairs should be done per the following general patterns.
The Authorized Person shall determine the final monitoring pattern. The pattern shall be documented in the test report.

X X
X
X
X X

X X X
X X X
X X X

A pattern as defined by the “X” marks is suggested if practical

FIGURE 5.1.9.3: GENERAL PATTERN FOR CIRCUIT MONITORING

NOTE: Monitored terminals shall not be the same samples used for subsequent Dry Circuit readings for record, since the
monitoring equipment may cause the potential across the circuit to exceed 20 mV. Dry Circuit readings, however,
may be taken as an aid in root-cause diagnosis.

Solder the conductors from each terminal in the CUT in series to form one continuous current path with only two free ends.
Solder one of the free conductor ends to a 2 W, 120 Ω ± 1.2 Ω resistor. Solder the "−" (negative) lead to the free end of the
resistor and the "+" (positive) lead to the remaining free conductor end of the CUT. Connect the Continuity Tester across
the resistor, making sure that the negative lead of the CT is connected to the negative side of the resistor. Adjust the power
supply to provide 100 mA to the circuit. Set the CT to monitor the current through the resistor and record any instance where
that current falls below 95 mA. As an option, the CT may be used to monitor one or more terminal pairs instead of the
resistor. A reference illustration of the test set-up is shown in Figure 5.1.9.3. Other suitable continuity monitoring equipment
may be used. The test fixtures, system layout, and test set-up must be approved by the Authorized Person prior to testing.
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FIGURE 5.1.9.3: CONNECTOR ENVIRONMENTAL TEST SET-UP

5.1.9.4 Acceptance Criteria

Where continuity monitoring is required during any conditioning procedure, there must be no loss of electrical continuity
(any instance of the resistor current dropping below 95 mA), for more than 1 µs. If one or more terminal pairs are monitored,
rather than the series resistor, there must be no instance in which the resistance of any terminal pair exceeds 7.0 Ω for
more than 1 µs. Figure 5.1.9.4 illustrates the acceptance criteria graphically.

Contact
Acceptable
Resistance

Not
Acceptable

7 ohm

Time

1µs

FIGURE 5.1.9.4: INTERMITTENCY MEASUREMENT

5.1.10 Mat Seal Sample Preparation

5.1.10.1 Purpose

This procedure preconditions a multi-cavity (mat) seal of a sealed connection system to ensure the sealing performance
within the design-intent cable size range and that the terminal does not damage the seal during service operations.

5.1.10.2 Equipment

None.
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5.1.10.3 Samples

Prepare two sets of ten CUT samples. Number each connector pair.

1. Ten samples prepared with terminal samples per 5.1.6 using the smallest conductor size and insulation thickness
applicable to the design of the terminal to be tested and to fully populate the CUTs.

2. Ten samples prepared with terminal samples per 5.1.6 so that all but one cavity in each connector is populated with a
terminal crimped to the largest applicable conductor size. The one exception is the cavity located farthest from the
connector center. Fill that cavity with the appropriate terminal crimped to the smallest applicable conductor size.

5.1.10.4 Procedure

Select ten cavities at random among each sample set per 5.1.10.3 and record the connector and cavity numbers. Remove
and re-insert the terminals in the selected cavities twice (insert-remove-insert-remove-insert).

5.1.10.5 Acceptance Criteria

None.

5.2 Terminal Mechanical Tests

5.2.1 Terminal to Terminal Engage/Disengage Force

5.2.1.1 Purpose

This test determines the engage and disengage forces of compatible male and female terminal pairs. Determination of the
number of terminals that can be packaged in a given connector design without exceeding allowable mating force limits is
dependent on this information. Note that this test is written so that only the first engagement and the last (tenth)
disengagement are recorded and used to verify compliance with the Acceptance Criteria.

5.2.1.2 Equipment

• Insertion/retention force tester with peak reading feature

• Polished steel gage (optional)

5.2.1.3 Procedure

1. Completely identify and number each terminal to be tested. A minimum of 20 samples (ten male and ten female) are
required. If the optional step 8 is to be used, at least an additional ten female terminal samples will be required.

2. Fixture one Male and one female terminal so that proper alignment is achieved during testing.

3. Engage the mating terminals at a uniform rate not to exceed 50 mm/min. The force shall be applied parallel to the
centerlines of the terminals. Proper alignment of the terminals is critical to avoid side loads and binding which can
adversely affect the force measurement.

4. Record the peak force required to completely engage the terminal to its mating part. This force is recorded for
information and is not used in the Acceptance Criteria

5. Disengage the mated terminals at a uniform rate not to exceed 50 mm/min. The force shall be applied parallel to the
centerlines of the terminals.
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6. Repeat steps 3 and 5 nine more times at a rate not to exceed 100 mm/min (no readings are taken). Record the tenth
disengage force reading taken at a rate not to exceed 50 mm/min. This force is recorded for information and is not used
in the Acceptance Criteria.

7. Repeat steps 2 to 6 for each pair (one male and one female) of sample terminals.

8. (Optional gage test) Repeat steps 2 to 7 except use the applicable gage in place of the male terminals. Use new female
terminals. The applicable gage is to be of polished steel made to within 0.01 mm of nominal. Surface finish must be
0.076 to 0.305 µm (3 to 12 µin). Polish direction must be parallel to the blade/pin length. Test the additional ten
production female terminal samples to determine the force correlation between polished gage and actual samples.

5.2.1.4 Acceptance Criteria

Complete the Visual Examination per 5.1.8 noting any wear of the contact surfaces. No base material should be exposed.

5.2.2 Terminal Bend Resistance

5.2.2.1 Purpose

This test checks for terminal resistance to bending or breaking during crimping, assembly, or service. Insufficient bend
strength for the conductor size selected can lead to a high incidence of terminal damage during the assembly process.
Since terminal material thickness varies so widely, and the bending force can be applied in any direction, only minimum
values have been assigned to this test. Actual bending force values in each of three directions are recorded and it is then
up to the Authorized Person to evaluate the results and determine the suitability of the tested terminal for its intended
application.

NOTE: This test is not applicable to terminals where the wire attachment is 90 degrees to the direction of insertion.

5.2.2.2 Equipment

• Steel mounting fixture(s) appropriate to the terminal(s) under test

• Crosshead-style force tester with measurement capability (or weights) capable of forces in Table 5.2.2.4

5.2.2.3 Procedure

1. From Figure 5.2.2.3-1, determine which design style most closely resembles the terminal under test (TUT).

2. For Style "A" terminals, prepare a total of at least 15 samples. For Style "B" terminals, prepare a minimum of
30 terminals, in order to test both bend locations.

FIGURE 5.2.2.3-1: TERMINAL DESIGN STYLE

3. Number each terminal. (Use at least 5 new samples for each test sequence, steps 6 to 9.)

4. Mount the TUT in a fixture taking care that location "1" is positioned as shown in Figure 5.2.2.3-2.

5. Apply force to the sample as shown in figure 5.2.2.3-2, then release. The required forces by terminal nominal size are
listed in table 5.2.2.4.
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6. Inspect the area around the bend using at least 10X magnification. Note in the test report any signs of metal cracking
or tearing. Straighten the terminal to its original position and re-inspect the terminal for cracks.

FIGURE 5.2.2.3-2: TERMINAL BEND TEST

7. Select a new batch of at least five samples and mount them in the test fixture with the terminal rotated 180 degrees
from the position shown in Figure 5.2.2.3-2. Repeat steps 5 to 7.

TABLE 5.2.2.4: APPLIED BENDING FORCE BY TERMINAL SIZE

Nominal Blade Size Applied Force

(mm) (N)
0.5 3.0
0.64 to <1.5 4.0
1.5 to <2.8 7.0
2.8 to <6.3 10.0
6.3 to <9.5 15.0
9.5 20.0

8. Select a new batch of at least five samples and mount them in the test fixture with the terminal rotated 90 degrees from
the position shown in Figure 5.2.2.3-2. Repeat steps 5 to 7. Since terminals are typically symmetrical in this “side to
side” direction, it is not necessary to test both directions. If the TUT is not symmetrical in this direction, it may be
necessary to test both ways.

9. For terminal style "B" designs (Figure 5.2.2.3-1), repeat steps 5 to 9 with each TUT mounted such that location "2" is
firmly retained at the edge of the fixture.

5.2.2.4 Acceptance Criteria

The TUT must not tear when subjected to the applied force. If the TUT was bent from its original position during the test, it
must not tear or crack when straightened to its original position.

NOTE: Most terminal and connector manufacturers have internal documentation regarding minimum terminal straightness
required for successful processing and quality. Consult the respective supplier(s) for these requirements. This test
does not override these requirements.
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5.3 Terminal - Electrical Tests

5.3.1 Dry Circuit Resistance

5.3.1.1 Purpose

This test determines the combined resistance of the two conductor crimps (or single crimp in the case of a Header
Connector) and the contact interface of a mated terminal pair in a connector, under low-energy conditions.

5.3.1.2 Equipment

• Micro-ohmmeter

5.3.1.3 Procedure

Take care to avoid any mechanical disturbance of mated terminal samples submitted for this test. Such disturbance could
rupture any insulating film which may have developed on the contact surfaces. If for any reason the terminals submitted for
this test are already contained in their mated connector housings, do not disconnect them unless otherwise directed by the
Authorized Person. This procedure is typically used for mated connectors but can also be used for mated terminal pairs
outside of a connector housing.

NOTE: Since this test is done to detect the presence of thin insulating films that may have developed on the contact
surfaces during field service or environmental type stress tests, it is important that no other electrical test be
performed on the samples prior to this test.

1. Prepare samples per 5.1.6, Terminal Sample Preparation, using the cable size per the appropriate Test Sequence
(Table 5.9) applicable to the design of the terminal to be tested. If terminals being tested are already inserted into a
connector housing, omit this step.

2. For terminals that have been subjected to prior testing, do not disconnect their connector housings or remove any
terminal from its housing.

3. Measure and record the resistance across 150 mm of the conductor to be used for the test. For tests using a Header
terminal as one half of the test connection, see 5.1.5 and measure only 75 mm (recommended length for most
applications) of the conductor.

4. For attachment points exceeding 75 mm per side, the extra wire resistance shall be measured and subtracted per
step 8. Record the conductor resistance.

5. Choose the preferred method of taking measurements (e.g., soldered sense lead or probe) and document the method
chosen. In either case, the sense point T1 (Figure 5.3.1.3) must be soldered for all stranded cable. For Header type
connectors, T2 is attached to the Header terminal per 5.1.5. Millivolt leads must be no larger than 0.22 mm2. Note that
Figure 5.3.1.3 shows terminals only but the same method of voltage probe attachment applies to terminals in
connectors.

FIGURE 5.3.1.3: TYPICAL CONNECTION RESISTANCE MILLIVOLT LEAD LOCATIONS

(SHOWN BEFORE MATING TERMINALS OR INSERTING TERMINAL INTO CONNECTOR)
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6. If sample is a terminal with no connector housing, the male terminal must be inserted to a precise depth into the female.
Standard practice is that, in the worst case, there must be at least 1 mm of excess insertion between the rearmost
contact point with the female terminal and the start of any lead-in taper on the male terminal, as illustrated in Figure
5.3.1.4. This dimension is to be calculated from the terminal drawings by the Authorized Person, taking into account the
worst-case tolerances. Each male terminal is to be suitably marked so test personnel can make the one and only mating
of the test terminal pairs to the correct depth. Score marks or any other marking that might introduce contaminants or
alter the strength or conductivity of the male terminal or the interface are not permitted.

FIGURE 5.3.1.4: TERMINAL INSERTION

7. If sample under test is a terminal pair with no connectors, provision must be made for mounting them on an electrically
non-conductive surface in such a manner that the mechanical stability of the male to female interface can be maintained.

8. Carefully mate the test connector or terminal pair. If the sample under test is a terminal, follow these additional
instructions: Mate to the appropriate depth, as specified in step 5 above. Use caution to assure that mating is done
along terminal centerlines to prevent side pressure that may distort either terminal. Secure the TUT to the mounting
surface so that the correct insertion depth is maintained throughout the test.

9. Using the appropriate equipment, measure and record the resistance between T1 and T2, as shown in Figure 5.3.1.3.
Then deduct the conductor resistance to find the total connection Dry Circuit resistance.

10. Verify conformance to the Acceptance Criteria of 5.3.1.4.

NOTE: Taking both initial and post-test dry circuit resistance measurements is suggested. Initial values are for
information only and do not have pass/fail requirements. These values can be used to compute resistance
change.

5.3.1.4 Acceptance Criteria

The Total Connection Resistance calculated in step 9 must not exceed the values listed in Table 5.3.2.4.

For connectors with Shorting Bars, the change in connection series resistance of both contacts while in the “shorted” position
shall be <40 mΩ. Other requirements may apply depending on the purpose of the shorting circuit.
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5.3.2 Voltage Drop

5.3.2.1 Purpose

This test determines the voltage drop associated with the electrical resistance of the conductor crimp(s) and contact
interface regions at specific current conditions. This voltage drop is then used to calculate the Total Connection Resistance
of the CUT.

5.3.2.2 Equipment

• Digital multimeter (DMM)

• DC power supply (0 to 20 VDC at 0 to 150 A)

• Current shunts

5.3.2.3 Procedure

1. Prepare samples per 5.1.6. Terminal Sample Preparation, using the cable size per the appropriate table Test Sequence
(5.9) applicable to the design of the terminal to be tested. If terminals being tested are already inserted into a connector
housing, omit this step.

2. If testing terminals outside of connectors, the male terminal must be inserted to a precise depth into the female. Standard
practice is that, in the worst case, there must be at least 1 mm of excess insertion between the rearmost contact point
with the female terminal and the start of any lead-in taper on the male terminal, as illustrated in Figure 5.3.1.4. This
dimension is to be calculated from the terminal drawings by the Authorized Person, taking into account the worst-case
tolerances. Each male terminal is to be marked so test personnel can make the final mating of the test terminal pairs to
the correct depth. Score marks or any other marking that might introduce contaminants or alter the strength or
conductivity of either terminal or the interface are not permitted. If testing terminals inserted into connectors (such as
when performing test groups M, N, O, or P), the connector housings control terminal location and no special depth
control is used.

FIGURE 5.3.2.3: TYPICAL CURRENT RESISTANCE TEST SET-UP

3. If testing terminals outside of connectors, provision must be made for mounting on an electrically non-conductive surface
in such a manner that the mechanical stability of the male to female interface can be maintained.
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4. Carefully mate the test terminal or connector under test. If testing terminals outside of connectors, mate the terminal
pair to the appropriate depth, as specified in step 2 above. Use caution to assure that mating is done along terminal
centerlines to prevent side pressure that may distort either terminal. Secure the TUT to the mounting surface so that
the correct insertion depth is maintained throughout the test.

5. Assemble the test circuit shown in Figure 5.3.2.3, Current Resistance Test Set-Up. Adjust the power supply to provide
the required test current of 5 A/mm2 of conductor cross section for the conductor selected in step 1. Refer to ISO 6722-1,
SAE J1127, or SAE J1128 for the cross-sectional area of the conductor selected. More than one terminal or connector
pair may be tested in series. See Figure 5.3.1.3 for Connection Resistance Millivolt Lead Locations, for placement of
the millivolt test leads. Record the test current used.

6. Measure and record the millivolt drop across the conductors only using the test current determined in step 5 (the
conductors will be 150 mm of the conductor size and insulation type to be used during the test for inline connections;
for Header type connectors, see 5.1.5 and measure the millivolt drop across only 75 mm of the conductor used). For
attachment points exceeding 75 mm ± 3 mm per side, the extra wire resistance shall be measured and subtracted per
step 9. It is recommended to attach sense leads for vibration beyond the initial retention point which will result in >75 mm
leads.

7. Choose the preferred method of taking measurements (soldered sense lead or probe) and document the method
chosen. In either case, the sense point T1 (Figure 5.3.1.3) must be soldered for all stranded cable. For Header type
connectors, T2 is attached to the Header terminal per 5.1.5. All millivolt leads must be no larger than 0.22 mm2.

8. Set the power supply for the current determined in step 5 and wait 30 minutes minimum to ensure that the test current
stabilizes at the appropriate value. Allow sufficient time for all other test equipment to warm and stabilize per the
manufacturer's recommendations.

9. Using the test current determined in step 5, measure and record the millivolt drop (mVD) readings between test points
T1 and T2. Use these values in the equation below to calculate the voltage drop across the entire connection, including
the crimp(s) and terminal interface. In the case of Header type connectors, T2 is attached to the "tail" of the Header
Connector per 5.1.5.

mVD of crimp and terminal = mVD (T1 - T2) - [mVD Conductor(s) measured in step 6] (Eq. 1)

Use these results to verify conformance to the Acceptance Criteria of 5.3.2.4. Values for terminal sizes between 0.50 mm
and 9.5 mm but not in the table are calculated by interpolation.

NOTE: These values apply both before and after any environmental or mechanical conditioning and to field samples.

5.3.2.4 Acceptance Criteria

For inline connectors, the mVD values calculated in step 9 shall meet requirements per Table 5.3.2.4.

NOTE: The values in the table defined as Total Connection Resistance are for "crimp and terminal" measurements (T1 to
T2 in Figure 5.3.2.3) less the appropriate conductor resistance. For headers, Total Connection Resistance values
are the “crimp- to- tail” (T1 to T2 in Figure 5.1.5) less the appropriate conductor resistance.
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TABLE 5.3.2.4: MAXIMUM VALUES FOR DRY CIRCUIT (5.3.1) AND VOLTAGE DROP FOR (5.3.2)

Total Precious Metal (1)

Nominal Male Connection Total Connection Maximum
Terminal Resistance Resistance Voltage Drop
Size (mΩ) Maximum (mΩ) Maximum (mV) (3)
0.50 mm 25.0 25.0 50
0.64 mm 20.0 10.0 50
1.2 mm 15.0 10.0 50
1.5 mm 10.0 10.0 50
2.8 mm 5.0 5.0 50
6.35 mm 1.8 (2) 1.8 (2) 50
9.5 mm 1.0 1.0 50
NOTES:
(1) Silver or gold top plating
(2) High-performance 6.35 mm terminals may require a tighter value. It is the connector makers

responsibility to identify high-performance parts and alternate criteria.

(3) For reference: 1 mΩ = 1 mV/A

5.3.3 Maximum Test Current Capability

5.3.3.1 Purpose

This test is used to determine the maximum test current at which a terminal system can operate in a room temperature
environment before excessive thermal degradation and/or resistance begins to occur. Temperature Rise (Y axis) versus
Current (X axis) shall be plotted for each applicable conductor size. These graphs are NOT to be used for actual terminal
application in a vehicle (see Appendix F). This test is conducted on terminals alone, thus eliminating the variation that may
be introduced by variations in the heat dissipating characteristics of differing connector housing designs and sizes.

5.3.3.2 Equipment

• Digital multimeter (DMM)

• DC power supply (0 to 20 VDC at 0 to 150 A)

• Current shunts (size as required, ±1%)

• Thermocouples (Type "J" or "T")

• Data logger (as required)

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5.3.3.3 Procedure

1. Draft-free enclosure construction: A draft free environment is necessary to get accurate measurements. The samples
shall be mounted in an enclosure which protects the immediate environment from external movement of air. A “Draft
free” environment is indicated by an undisturbed vertical smoke plume of 150 mm (6 inches). A description follows:

Draft-free Enclosure Description:

• Construction: Made from a non-thermally conductive and non-heat reflective material. The sides of the enclosure may
be moveable to accommodate different specimen sizes. Access panels or doors are acceptable provided they do not
allow external air movement to enter the enclosure when closed.

• Top and Bottom: The enclosure may have a lid. Any such lid shall have sufficient openings or be of an open mesh or
screen or be raised above the sides to minimize any rise in ambient temperature caused by the heating effect of the
samples under test. The bottom of the enclosure shall be solid.

• Spacing of samples: Minimum spacing from the sides of the enclosure to the edges of the samples is 200 mm.
Minimum spacing between samples is 30 mm and should be sufficient so as to negate the effects of heating due to
proximity of samples.

• Sample orientation: Orient samples “horizontally” as best is possible and evenly distributed over the area of the
enclosure. As far as possible, the specimens shall be in free suspension. If this is not possible due to the need to
maintain specified contact insertion distance, a thermal insulating material with a thermal conductivity ≤0.2 W/mK may
be used, provided that not more than 20% of the surface of the specimen is in contact with the insulating material.

• Ambient Temperature Sensor: The measuring point for measuring the ambient temperature shall be located in a
horizontal plane passing through the axis of the specimens. It shall be located a minimum of 150 mm from any energized
sample. Care shall be taken to protect the probe against radiant heat.

• Wiring the circuit: The specimens shall be connected with wires of suitable cross-section for the maximum current to
be expected or according to the size of the termination. In order to reduce external heat dissipation to a minimum, at
least the length of the connecting wires given in Table 5.3.3.3 shall be within the measuring enclosure: This table is
based on heat conduction criteria and is designed to ensure that the wires are long compared with their cross-section.

TABLE 5.3.3.3: MINIMUM WIRE LENGTH

Minimum Wire Length

Wire Size (mm2) (mm)
<0.5 200
0.5 to 5.0 500
>5.0 500

2. Measure and record the voltage drop across 150 mm of the conductor to be used for the test, using the expected
Maximum Current Capability of the TUT in combination with that conductor size and insulation type. For testing Header
type connectors, see 5.1.5 and measure the millivolt drop across only 75 mm of the conductor used.
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FIGURE 5.3.3.3-1: TOP VIEW OF DRAFT-FREE ENCLOSURE FOR TERMINAL TESTING

FIGURE 5.3.3.3-2: SET-UP FOR MAXIMUM TEST CURRENT

FIGURE 5.3.3.3-3: DETAIL OF MILLIVOLT LEAD LOCATIONS FOR FIGURE 5.3.3.3-2

3. Assemble the circuit shown in Figures 5.3.3.3-2 in a draft free enclosure as described in 5.3.3.3 and Figure 5.3.3.3-1.
Use at least ten terminal pairs. Choose the preferred method of taking measurements (soldered sense lead or probe)
and document the method chosen. In either case, the sense point T1 (Figure 5.3.3.3-3) must be soldered for all stranded
cable. Attach conductor ends of the terminal pairs to form one continuous series circuit and attach the thermocouples
to each mated pair as shown in Figure 5.3.3.3-2. Mount the circuit in the draft-free enclosure.
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4. Test the sample terminal pairs at 23 °C ± 5 °C (room temperature).

5. Adjust the power supply to 0 A output and then turn on the supply and the DMMs.

6. Slowly increase the power supply output until it is providing no greater than 50% of the expected Maximum Current
Capability of the TUT.

7. Wait at least 15 minutes for the circuit temperature to reach Steady State (as defined in Appendix A). Then record the
ambient temperature, the temperature of each terminal pair interface and the millivolt drop across each terminal pair
(T1 to T2 in Figure 5.3.3.3-3 for inlines and 5.3.1.3 for headers, less the millivolt drop of the conductor as determined in
step 2). Then calculate the resistance of the terminal pair interface.

8. Increase the current by no more than 10% of the expected Maximum Current Capability of the TUT and repeat step 7.

9. Repeat steps 7 and 8 until one of the following conditions occurs:

a. The temperature of any terminal interface exceeds a 55 °C rise over ambient (ROA).

b. The total connection resistance or maximum voltage drop of any terminal interface exceeds the Acceptance Criteria
listed in 5.3.2.4.

c. Any TUT does not meet the Visual Acceptance Criteria listed in 5.1.8.4.

10. Save test set-up for subsequent tests (5.3.4).

* This optional step can be performed at this point with excess samples, if requested: Using samples that will not be
used in subsequent tests, continue to increase the current in steps of 5% of the Maximum Current Capability of the
TUT until the thermal stability of any one or more samples can no longer be achieved. Data from this “test to failure”
step may be useful for statistical purposes or for estimating safety margins.

11. Graph the data with temperature on the Y-axis and current (in amps) on the X-axis for all conductor sizes and insulation
types tested.

NOTE: That this data is NOT to be used as guidance for any actual application of the TUT; see Appendix F.

5.3.3.4 Acceptance Criteria

No pass/fail criteria apply; value is used to establish "Maximum Test Current" for the TUT in 5.3.4. The maximum test current
of the specific combination of the terminal and the wire conductor gage and insulation type used is the current that produces
an exact or interpolated value of 55 °C rise in the first increment in which either the condition described in 9 a or 9 b above
was achieved, less 10% of that value.

5.3.4 Current Cycling

5.3.4.1 Purpose

This test simulates the main function of power terminals over the expected life of the vehicle. Current cycling is an
accelerated aging test which electrically heats terminal interfaces and core conductor crimps, then allows them to cool under
zero current conditions, causing expansion and contraction that may affect connection resistance due to wear, oxidation,
inter-metallic growth and stress relaxation.
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5.3.4.2 Equipment

• Digital multimeter (DMM)

• DC power supply (0 to 20 VDC at 0 to 150 A, timer controlled)

• Current shunts (Size as required, ±1%)

• Thermocouples (Type "J" or "T" typically)

• Data logger (as required)

5.3.4.3 Procedure

1. Attach the millivolt leads in positions T1 and T2 as shown in Figure 5.3.1.3. For Header type connectors, T2 is attached
to the Header terminal per 5.1.5. Millivolt leads must be no larger than 0.22 mm2.

2. Measure and record the voltage drop across 150 mm of the conductor to be used for the test, using the maximum test
current previously determined (5.3.3.4) for the combination of that conductor size, insulation type and the TUT. For
testing Header type connectors, see 5.1.5 and measure the millivolt drop across only 75 mm of the conductor used. For
attachment points exceeding 75 mm, the extra wire resistance shall be measured and subtracted.

3. Assemble the circuit shown in Figure 5.3.3.3-2 in a draft free enclosure as described in 5.3.3.3, except use a
timer-controlled power supply. Set the power supply to provide 45 minutes on and 15 minutes off at the maximum test
current previously determined (5.3.3.3, step 9) for the combination of that conductor size, insulation type, and the TUT.
Connect a data logger to the voltage drop and thermocouple leads.

4. Test the set of sample terminal pairs at 23 °C ± 5 °C (room temperature). An ambient temperature sensor must be
placed on the same plane as the test samples, 150 mm min from the nearest sample.

5. Turn on the power supply, DMMs, and data logger.

6. After 30 minutes into the first on cycle, record terminal crimp and interface millivolt drop readings (T1 to T2 in
Figure 5.3.2.3) as well as thermocouple readings for each terminal pair.

7. Complete 1008 cycles taking readings at least once daily 30 minutes into the on cycle, and at the conclusion of the test,
30 minutes into the final “on” cycle. Millivolt drop readings should be taken at maximum test current.

8. For each set of data, calculate and record the Total Connection Resistance by subtracting the conductor millivolt drop
reading (step. 4) from the T1 to T2 millivolt drop reading (step 7) and dividing the result by the test current.

9. Allow the samples to cool to ambient, then measure CUT/TUT as required per appropriate test sequencing table.

5.3.4.4 Acceptance Criteria

1. At the conclusion of the test, verify conformance of CUT/TUT per corresponding measurement section as identified in
Test Sequence (5.9).

2. The temperature of any terminal interface must not exceed a 55 °C ROA at any time during the test.

3. The total connection resistance or maximum voltage drop of any terminal interface reading shall not exceed the
Acceptance Criteria listed in 5.3.2.4.
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5.4 Connector - Mechanical Tests

5.4.1 Terminal - Connector Insertion/Retention and Forward Stop Force

5.4.1.1 Purpose

This test is required to in order to measure the Insertion Force of a terminal into its connector cavity. Retention testing is
required to ensure that the terminal is retained in its housing with sufficient strength to withstand the rigors of the wiring
harness and vehicle assembly processes.

5.4.1.2 Equipment

• Insertion/retention force tester with peak reading feature

• Temperature/humidity chamber capable of 95 to 98% RH at 40 °C

5.4.1.3 Procedure

A. INSERTION FORCE:

Un-Sealed Connectors and Sealed Connectors with Individual Cable Seals

1. Prepare terminal samples per 5.1.6, using the largest gage size conductor and insulation thickness applicable to the
design of the terminal to be tested. For connectors with ten or more terminal cavity locations, use a minimum of three
connector housings and prepare at least one terminal for each cavity location. Test each terminal cavity location in the
CUT at least once. For connectors with four to nine terminal cavity locations, use a minimum of three connector housings
and prepare enough terminal samples to test each cavity location in each CUT. For connectors with three terminal
cavity locations, use a minimum of four connector housings and prepare enough terminal samples to test each cavity
location in each CUT. For connectors with one or two cavity locations use enough connector housings to obtain at least
ten data points and test all cavity locations an equal number of times. See Table 5.4.1.3.1. Use sample sizes and cavity
requirements from the table for insertion, retention, forward stop and after conditioning force measurements. If CUT has
a mat seal, jump to the mat seal section for sample requirements and process steps.

TABLE 5.4.1.3.1: SAMPLE SIZES AND CAVITY REQUIREMENTS

# of Terminal Minimum # Minimum # of Cavity Locations Minimum # of

Cavity Locations of CUTs Terminal Samples Tested Data Points
= # of Terminal Each location at least = # of Terminal
10 or more 3
Cavity Locations once Cavity Locations

Each location 3X or
= # of Terminal = # of Terminal
Same num CUTs or
4 to 9 3 Cavity Locations Cavity Locations X #
each location the
times # of CUTs of CUTs
same num. of times
= # of Terminal
Each location an
3 4 Cavity Locations 12
equal number of times
times # of CUTs
Each location an
2 5 10 10
equal number of times
Each location an
1 10 10 10
equal number of times

2. If more than one wire size is applicable to the CUT and terminal, create additional samples per step 1 but use the
smallest conductor size and insulation type applicable to the design.
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3. Number each connector terminal cavity and, if applicable, each connector.

4. Secure the connector shell in an appropriate fixture.

5. Secure the terminal sample in the force tester by gripping the conductor a minimum of 20 mm behind the insulation
grip.

6. Adjust the force tester to insert the terminal straight into the connector at a uniform rate not to exceed 50 mm/min. Note
peak insertion force. Continue to test using a fresh terminal sample for each insertion and test each terminal cavity
location until all terminal samples prepared in step 1 have been used. Continue applying force until failure point of the
forward stop is reached. Where wire buckling and operator sensitivity cause problems in obtaining test repeatability,
one of two alternatives are acceptable. (A) Terminals may be crimped to a gage pin, solid core wire or other metal dowel
material, or (B) Terminals may be pushed by cutting the wire off the CUT near the insulation grip and use a rod with a
diameter similar to the cut-off wire and then push on the wire stub. Samples prepared using Option B cannot be used
for terminal-to-connector retention tests.

7. Repeat step 6 using samples prepared in step 2 (smallest conductor size) until peak insertion force is measured
(forward-stop test is not required). Repeat until all terminal samples prepared in step 2 have been used.

8. Record the force required to insert the terminal into the connector for each terminal sample. For samples prepared in
step 1 only, record the force at failure of the forward stop. Assess conformance to the Acceptance Criteria of 5.4.1.4.

Alternate Instructions for Connectors with Multi-Cavity (Mat) Seals

1. Prepare two sets of samples per Unsealed Connectors and Sealed Connectors with Individual Cable Seals per step1
above and one set of samples per Unsealed Connectors and Sealed Connectors with Individual Cable Seals per step
2 above.

2. Complete steps 3, 4, and 5 above.

3. Insert one set of terminals made in step 1 per step 6 above and in step 2 per step 7 above. For mat seals, each test
sample lead may be removed after its cavity is tested. This is to prevent possible seal distortion or compression that
might affect test results if neighboring seal holes remain filled. For connectors with fewer than ten cavities, use a new
connector after each terminal cavity in the first connector has been tested and continue until at least ten terminal
samples have been used.

4. With the extra set of samples prepared in step 1 above, use the force tester as in step 3 above, load each terminal into
a separate cavity without removing samples previously inserted. Perform the test in such a sequence that the last cavity
to be tested is as centrally located as possible. In addition to the data required in step 5 below, record the cavity number,
the Insertion Force and the order in which the cavities were tested.

5. Record the force required to insert the terminal into the connector for each terminal sample tested and verify
conformance to the Acceptance Criteria of 5.4.1.4.

6. Repeat steps 4 to 5 using the samples with the smallest conductor/insulation type appropriate to the design.
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B. RETENTION FORCE:

Retention testing is required to ensure that the terminal is retained in its housing with sufficient strength to withstand the
rigors of the wiring harness and vehicle assembly processes.

1. Prepare terminal samples per 5.1.6, using the largest gage size conductor and insulation thickness applicable to the
design of the terminal to be tested. For connectors with ten or more terminal cavity locations, use a minimum of three
connector housings and prepare at least one terminal for each cavity location. Test each terminal cavity location in the
CUT at least once. For connectors with four to nine terminal cavity locations, use a minimum of three connector housings
and prepare enough terminal samples to test each cavity location in each CUT. For connectors with three terminal
cavity locations, use a minimum of four connector housings and prepare enough terminal samples to test each cavity
location in each CUT. For connectors with one or two cavity locations, use enough connector housings to obtain at least
ten data points and test all cavity locations an equal number of times. See Table 5.4.1.3.1.

NOTE: Solder may be added to terminal crimps to assure accurate retention readings. Connectors are to be tested in
“dry as molded” condition and should be protected from high humidity and heat levels between the time they
are molded and the time they are tested.

2. Number each connector terminal cavity in each connector housing so there are no duplicate cavity numbers among the
housings used.

3. Install a terminal sample into each cavity in the connector being tested. For connectors with less than ten cavities, use
a new connector after each terminal cavity has been tested and continue until all ten terminal samples have been used.
Do not install the terminal lock (PLR, TPA, wedge, etc.).

4. Secure the connector shell in an appropriate fixture.

5. Secure the terminal sample in the force tester by gripping the wire behind the back edge of the terminal.

6. Adjust the force tester to pull the terminal straight back from the connector. Straight back force is critical to avoid side
loads and binding which can affect force measurements. Increase the pullout force at a uniform rate not to exceed
50 mm/min, until pullout occurs.

7. Record the force required to pull the terminal out of each terminal cavity along with the cavity number and the connector
number. If the conductor breaks or pulls out of the terminal grip before the terminal is pulled from the connector, record
this force together with a note as to what happened.

8. Repeat steps 1 to 3 and, if applicable, install the terminal secondary lock (PLR, TPA, wedge, etc.). Subject the samples
to moisture conditioning (bring to the practical limit of moisture content by exposing “dry as molded parts” to 95 to 98%
Relative Humidity at 40 °C for 6 hours followed by 1 hour at room ambient temperature and humidity. Repeat steps 1 to
7 above. Complete the retention test of all samples within 8 hours.

NOTE: Samples may be sealed in non-moisture transferable plastic (Ziploc-type food storage) bags after moisture
conditioning if the testing cannot be completed within 8 hours. In any case testing must be completed within
24 hours of moisture conditioning.)
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5.4.1.4 Acceptance Criteria

Insertion:

1. The Insertion Force for a terminal shall not exceed 15 N for terminal sizes between 0.5 mm and 1.2 mm; 20 N for blade
sizes bigger than 1.2 mm and less than to 2.8 mm; and 30 N for blade sizes >2.8 mm.

2. The forward stop (tested in 5.4.1.3 A6) push-through force shall be ≥35 N for 0.50 mm terminals and ≥50 N for >0.50 mm
terminals.

Retention:

The minimum retention force of a terminal from its cavity shall meet the values shown in the table 5.4.1.4.

NOTE: For connectors not designed with a secondary lock, use the criteria listed under the Primary + Secondary Lock
columns.

TABLE 5.4.1.4: TERMINAL-CONNECTOR MINIMUM RETENTION FORCE

Primary + Secondary Lock

Primary + Secondary Lock after Cavity Damage,
Max Nominal Primary Lock Retention after Moisture Conditioning Temp/Humidity and HTE
Blade Width (see 5.4.1.3.B6) (see 5.4.1.3.B8) (see 5.4.9, 5.6.2, 5.6.3)
(mm) (N) (N) (N)
0.50 20 40 40
0.64 30 60 50
1.2 40 70 50
1.5 45 70 50
2.8 60 100 70
6.3 80 130 90
9.5 100 150 140
NOTES:

• Primary lock retention is a harness manufacturing requirement.

• Primary and secondary lock is a vehicle assembly requirement

• Temperature humidity cycling and high temperature exposure are service/performance requirement to end-
of-life

5.4.2 Connector-Connector Mating/Unmating/Retention/Lock Deflection Forces (Non-Assist)

5.4.2.1 Purpose

This test determines the mating/unmating forces associated with manual mating and unmating of connector assemblies.
mating forces are an important consideration in determining the suitability of a given connector design for use in production.
unmating and retention forces are important in determining serviceability of the design and ensuring the connection will stay
mated for the service life of the vehicle.

5.4.2.2 Equipment

• Insertion/retention force tester

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5.4.2.3 Procedure

A. MATING FORCE

1. Using any applicable conductor size and insulation type, prepare enough samples of male and female terminals to fully
populate a minimum of 15 connector assemblies per 5.1.6, Terminal Sample Preparation (at least 15 male and
15 female halves).

2. Completely assemble (but do not mate) all connector halves (both male and female) using all applicable components
such as terminals, wedges, and seals.

3. Number each connector assembly.

4. Secure the connector halves (one male and one female) in the appropriate fixtures of the force tester. Adjust the force
tester to insert the male connector straight into the female connector. Straight-in engagement is critical to avoid side
loads and binding which can affect force measurements.

If appropriate equipment is available, a continuous

graph of applied mating force versus insertion distance
is highly recommended. A properly designed connector
(and sealing system where applicable) should produce
a graph showing a smooth rise to a single peak force
then a fall-off until the connector is fully mated. If the
graph shows more than one force peak, the potential for
a false lock condition exists.

FIGURE 5.4.2.3: TYPICAL CONNECTOR MATING FORCE CURVE AND EXPLANATION

5. Increase the mating force at a uniform rate of 50 mm/min ± 10 mm/min until complete mating occurs. Test all samples.

6. Record the force required to completely mate each set of connector halves into their locked position and use these
values to verify conformance of each connector pair to the Acceptance Criteria of 5.4.2.4.

B. UNMATING/RETENTION FORCE

1. Prepare five connector pairs without terminals or wires and five connector pairs loaded with the appropriate wires and
terminals for step 5. (NOTE: It is permissible to use samples from Section A: mating force provided that the samples
remain in the mated state and without any other conditioning.) Completely mate all connector pairs.

2. Five samples are to be tested with the connector primary locking mechanism (without CPA) fully engaged. For this
group, completely unmate the connector halves by applying a uniform force parallel to the centerlines of the fully mated
connector halves. The force tester must be configured to apply the unmating force directly to the connector halves.
Straight-out unmating is critical to avoid side loads and binding which can affect force measurements.

NOTE: For connectors with lock arms that protrude above the protective ribs, run this test with the lock arm deflected
to make the highest point of the arm level with the protective ribs.
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*** CAUTION ***

The following step will result in sample breakage. Adequate shielding and personnel safeguards must be employed to
ensure the safety of persons and property in the vicinity of the test.

3. Increase the retention force at a uniform rate not to exceed 50 mm/min until complete separation occurs. Test all
samples in the first group.

4. Record the force required to completely separate the connector halves and verify conformance to the Acceptance
Criteria of 5.4.2.4.

5. Repeat steps 2, 3 and 4 above with the primary connector locking mechanism(s) completely disabled using the five
mating connector samples loaded with terminals.

C. LOCK DEFLECTION FORCE

1. Prepare five connector pairs without terminals or wires but include any auxiliary pieces that attach to the lever such as
CPAs. Completely mate all connector pairs. Gradually apply a force to the lock release button. Stop the force at 6 N
and verify the lock mechanism remains locked using an applicable evaluation method. Continue force application up to
51 N, or until the lock mechanism has clearly moved far enough to avoid contact with the lock feature on the mating
part if unmating is attempted. If practical, record force when the lock just barely clears the mating part’s lock feature.
(Apply this force at an appropriate point so that the mated connector parts can be unmated in the intended manner with
no damage to any component.) Record whether the connection can be successfully unmated at 6 N and 51 N.

2. If applicable, fully engage the CPA into the final lock position. Gradually apply a force of 70 N to the lock release button.
Look to see if the lock mechanism clears the lock feature. Pull on connector to see if connector disengages.

3. Record results and verify conformance to the appropriate Acceptance Criteria of 5.4.2.4.
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5.4.2.4 Acceptance Criteria

TABLE 5.4.2.4: CONNECTOR-CONNECTOR MATING/UNMATING/RETENTION/LOCK DEFLECTION FORCES

Connector-Connector Mating/Unmating/Retention/Lock Deflection Forces

No. of Terminals
Test Connectors installed? Accept. Criteria
Conn. mating 15 Yes Per SAE/USCAR-25 (a, c)
Conn. unmating 5 Yes ≤75 N
Conn. retention 10 No ≥110 N (b)
Lock deflection w/o CPA 5 No 6 to 51 N
Lock deflection w/CPA Latch does not move
5 No
with 70 N applied above the locking feature (d)
NOTES:

(a) The maximum mating effort is meant to simulate assembly in a vehicle when the
assembler's body position and access to the connector being mated is not
physically restricted. This specification will cover most operations, but not all
conditions of vehicle assembly and connector location can be anticipated.

(b) The forces specified in the Acceptance Criteria shall be met regardless of the
moisture content of the connector housing material. Consult the test request/order
to determine if any conditioning of the test samples is required prior to testing.

(c) The acceptance criteria for connector mating forces in this section vary with the
available finger contact area of the connector being tested. Refer to SAE/USCAR-
25 Electrical Connector Assembly Ergonomic Design Criteria for specific
acceptance criteria.

(d) In connector designs where it is difficult to apply pressure to the latch while
unmating the connector, it is permissible to visually confirm the latch does not clear
the locking feature with 70 N applied to the locking provision.

5.4.3 Connector to Connector Mate/Unmate Forces (Mechanical Assist)

5.4.3.1 Purpose

This test covers mating and unmating forces for Mechanical Assist connectors such as lever and slide lock. USCAR-25
Ergonomic guidelines should be used as a further reference.

5.4.3.2 Equipment

• Force tester

• Fixtures for holding connectors as required

5.4.3.3 Procedure

Sample preparation:

Tests A, B, and C: Minimum ten connector samples each. Using any applicable conductor size and insulation type, prepare
enough samples of male and female terminals to fully populate connector assemblies per 5.1.6, Terminal Sample
Preparation. Prepare connector samples with the full complement of wires, terminals, and secondary pieces as specified in
the design and intended for the production application.
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Test D: Prepare six connector pairs by mating male to female housings without terminals or wires.

Test E: Prepare five connector pairs without terminals or wires

A. FORCE TO ENGAGE/UNSEAT TO/FROM PRE-LOCK POSITION

Using the force tester, at a rate of 50 mm/min ± 10 mm/min, engage each connector fully to its pre-lock position. The pre-lock
position is defined as the point where the connector is positioned on the mating part and the mechanical assist is ready to
be activated. Connectors are normally held in the pre-lock position by detents.

1. Reverse the direction and measure the force required to un-seat the connector from the pre-lock position.

2. Verify conformance to the acceptance criteria of 5.4.3.4-1 and 5.4.3.4-2.

B. FORCE TO RELEASE LATCH FROM PRE-STAGE POSITION

NOTE: Connectors may be required to be shipped as part of a wiring assembly with levers or mechanical slides locked in
the “open” or “pre-stage” position. This eliminates un-necessary operations at the vehicle assembly plant. This part
of the test procedure measures the ability of the connector mechanical assist to remain open during shipping and
handling.

1. Using the unmated connector, place lever or slide in its shipping (open) position.

2. Determine the force class of the connector from USCAR-25. Using the force tester, apply the appropriate force to the
lever slide at a rate not to exceed 50 mm/min to move the lever/slide toward the lock position.

a. Class 1 connectors (15 mm2 push area per USCAR-25, Table 4.1)

b. Class 2 connectors (115 mm2 push area per USCAR-25, Table 4.1)

c. Class 3 connectors (230 mm2 push area per USCAR-25, Table 4.1)

3. Verify conformance to the acceptance criteria of 5.4.3.4 #3.

C. LEVER ACTUATION/REMOVAL FORCE

1. With the connector in its pre-stage condition, measure the force required to fully actuate and close the lever at a rate
not to exceed 50 mm/min. Force shall be applied perpendicular with the contact surface of the lever or slide as nearly
as possible.

2. For designs with a secondary release mechanism, without disabling or releasing this feature, apply a force of 60 N at a
rate not to exceed 50 mm/min to the lever in the release direction.

3. Disable or release any existing release mechanism (if applicable). Move lever of CUT from locked to open position
using a test speed not to exceed 50 mm/min. Record the force required to move the lever from the locked position to
the open position.

4. Verify conformance to the acceptance criteria of 5.4.3.4-4 and 5.

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D. CONNECTOR TO DEVICE OR CONNECTOR TO CONNECTOR LATCH RETENTION FORCE.

1. Mount the mated connectors in a fixture so as not to distort the housings or any of their associated parts. With connector
to connector locking feature enabled, pull the connectors apart at a rate not to exceed 50 mm/min using a suitable force
tester and measure the peak force required to separate the connectors. CPAs and or secondary locks shall be disabled
for this test. Repeat on four additional samples. (Test five samples.) Verify conformance to 5.4.3.4-6.

2. Mount one mated connector in a fixture so as not to distort the housings or any of their associated parts. With primary
connector to connector locking feature disabled (lever or slide open), pull the connectors apart at a rate not to exceed
50 mm/min using a suitable force tester and measure the peak force required to separate the connectors. CPAs and or
secondary locks must be disabled for this test. Verify conformance to 5.4.3.4-7.

E. LEVER RELEASE LATCH ACTUATION FORCE

1. With the samples completely mated, gradually apply a force of up to 51 N to the lock release button until the lock
mechanism clears the lock feature (allowing the lever/slide to move toward the disengaged -open- position. This force
is applied at the appropriate point such that the lever/slide can be moved in the intended manner with no damage to
any component. Note whether the lever/slide can be moved to the open position.

2. Record results and verify conformance to the appropriate Acceptance Criteria of 5.4.3.4-8.

3. If applicable, fully engage the CPA into the final lock position. Gradually apply a force of up to 70 N to the lock release
button and hold the force. Look to see if the lock mechanism clears the lock feature. Pull on connector to see if connector
disengages.

4. Record results and verify conformance to the appropriate Acceptance Criteria of 5.4.3.4-9.

5.4.3.4 Acceptance Criteria

Note that the acceptance criteria of this section vary with the available contact (grip) area of the connector being tested.
Refer to SAE/USCAR-25 Electrical Connector Assembly Ergonomic Design Criteria for details of the acceptance criteria.

1. The force to engage the connector to its pre-lock position shall meet the requirements of SAE/USCAR-25.

2. The force required to release the connector from its pre-lock position shall be between 15 N and 75 N.

3. The force to move the lever/slide from its shipping position while the connector is not in its pre-stage position shall be
60 N min for Class 1 and 2 connectors (as defined in USCAR-25, Section 4.1) and 90 N min for Class 3 connectors (as
defined in USCAR-25, Section 4.1).

4. The force required to move the lever to and from the locked (engaged) position shall meet the requirements of
SAE/USCAR-25.

5. The minimum force to release the assist feature without depressing the release mechanism (if applicable) shall be
≥60 N for a fully mated connector.

6. unmating force must be ≥110 N with the primary connector lock fully engaged. A CPA device, if provided for, must NOT
be engaged during this test.

7. unmating force must be ≤75 N with the primary connector lock completely disengaged/disabled.

8. The force to completely disengage the secondary connector lock shall be between 6 N and 51 N, inclusive, in its fully
seated position (without the CPA engaged).

9. The primary connector lock must not deflect enough to clear the mating locking (shark fin) feature or be easily separated
when pulled on when subjected to 70 N force with CPA engaged (see 5.4.3.3.E3).
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5.4.4 Polarization Feature Effectiveness

5.4.4.1 Purpose

This test ensures that the polarization feature(s) is adequate to meet its purpose of (a) preventing incorrect mating of a
connector housing, (b) preventing mating of a connector housing with any unintended mate, and (c) test the adequacy of
the polarization feature(s) in preventing terminal damage during incorrect assembly attempts.

5.4.4.2 Equipment

• Insertion/retention force tester with peak reading feature

• 9 VDC continuity meter ranging from 50 to 500 Ω with audible alarm

5.4.4.3 Procedure

1. Two factors must be considered: attempting to incorrectly mate two connector halves, or a connector half and a header
that are supposed to mate if properly oriented, and attempting to mate a connector with an incorrect mate.

2. Sample size varies depending on the number of incorrect orientations tested. Test at least one sample set for each
selected mis-orientation or mis-index.

3. Connectors are to be loaded with a complete compliment of male and female terminals. In place of terminals a suitable
mechanical or electrical means may be devised to detect penetration of one half of the CUT into the other to a depth
sufficient to contact any male terminal in any position if that male terminal was installed.

4. Orient the CUT with any possible mate in the same family in one or more incorrect orientations chosen by the Authorized
Person as most likely to defeat the polarization. The parts should be tested as follows, using a fresh sample of each
half for each orientation:

a. The correct orientation, but with the wrong index

b. The incorrect orientation

5. Secure the connector halves (or connector and header) (one male and one female) in the appropriate fixtures of the
force tester. Adjust the force tester to attempt insertion of the male connector into the female connector in the orientation
selected in step 3.

6. Attempt to engage the connector halves at a rate not to exceed 50 mm/min until a force of 3X the maximum value of a
properly mated connector (with force being ≥60 N and ≤150 N) is applied (see 5.4.2 or 5.4.3.3-A). For connectors with
Mechanical Assist, use 3X the maximum measured force to engage to pre-lock position (but not to be less than 60 N or
greater than 150 N) per 5.4.3.3-A. Hold force for 3 seconds. Note the indication of the penetration detection device
installed in step 3 if present.

7. Complete an expert evaluation. This evaluation shall be conducted among knowledgeable individuals trying “hands-on”
mis-mating to evaluate the effectiveness of the polarization features.
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5.4.4.4 Acceptance Criteria

1. The connection system must withstand a mis-mating force as specified in step 6 without damage to the connector and
no electrical contact shall be made between the male/female terminals. If sufficient mis-mating is achieved to allow
contact with any properly installed male terminal in any position in its connector housing, the polarizing feature(s) is
considered to be inadequate

2. After an expert evaluation has been conducted, the design must be considered effective in “hands-on” mis-mating
attempts.

NOTE: There may be cases where all polarizations for a given design are not available (i.e., not tooled) and therefore
cannot be tested. In such cases, state these exceptions in the DVP&R.

5.4.5 Miscellaneous Component Engage/Disengage Force

5.4.5.1 Locator Clips, Wire Dress Features, and Loose Piece TPA/PLR/ISL

5.4.5.1.1 Purpose

This test is done to ensure that connector assembly components such as locator clips, wire dress features, etc. will be
sufficiently retained yet allow easy and consistent assembly and removal for service.

5.4.5.1.2 Equipment

• Insertion/retention force tester with peak reading feature

5.4.5.1.3 Procedure

A. ENGAGEMENT FORCE

1. Completely identify and number each component to be tested. A minimum of ten samples is required to be tested for
each of the applicable conditions found in the acceptance criteria. The same samples may be used for various phases
of testing.

2. All components to be tested and their mating parts must be fixtured so that proper alignment is maintained during
testing. Straight-in engagement and extraction are critical to avoid side loads and binding which can affect force
measurements.

3. Engage each component to be tested, with its retaining mechanism in place at a rate not to exceed 50 mm/min. Test
each applicable condition per Table 5.4.5.1.4.

4. Record the force required to completely engage the component with its mating part and use this value to verify
conformance to the Acceptance Criteria of 5.4.5.1.4.

B. DISENGAGING FORCE

*** CAUTION ***

The following step may result in sample breakage. Adequate shielding and personnel safeguards must be employed to
ensure the safety of persons and property in the vicinity of the test.

1. With the component fully installed and properly fixtured, disengage the component at a rate not to exceed 50 mm/min.
The force must be applied parallel to the centerline of the component being tested to avoid side loads and binding which
can affect force measurements. The direction must be opposite to the direction of normal insertion of the component
part. Test each applicable condition per Table 5.4.5.1.4.

2. Record the force required to disengage the component from its mating part without releasing any latch feature if it exists
and use this value to verify conformance to the Acceptance Criteria of 5.4.5.1.4.
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3. For locator clips only, repeat step 1 above in each of the three directions 90 degrees, 180 degrees, and 270 degrees
from the initial insertion direction. Repeat step 1 in a direction orthogonal to the plane of the first four tests. Do not
exceed a force of 110 N for any of these subsequent tests. Use fixture identified in Figure 5.4.6.3A.

5.4.5.1.4 Acceptance Criteria

Insertion/retention forces shall meet the shown in Table 5.4.5.1.4.

TABLE 5.4.5.1.4: MISC. COMPONENT AND LOOSE PIECE TPA/PLR/OR ISL ASSEMBLY FORCES

Insert to lock Force Remove Force

Device (N) (N)*
Component with positive retaining 110 min if feature is not a clip slot
feature such as locator clip, wire 60 max 110 min for clip slots ≤11 mm wide
dress, etc. 165 min for clip slots >11 mm wide
60 max (w/terminals installed in
Loose piece TPA/PLR/or ISL 25 min
all available cavities)
* Note that 5.4.11 must also be completed for locator clips in all directions except F5.

5.4.5.2 Pre-Staged CPA/TPA/PLR/ISL Engage/Disengage Force

5.4.5.2.1 Purpose

This test is completed to ensure that connector secondary locking features will be sufficiently retained in shipping and will
remain in their intended position until intentionally activated to close or remove for service.

5.4.5.2.2 Equipment

• Insertion/retention force tester with peak reading feature

5.4.5.2.3 Procedure

A. ENGAGEMENT FORCE - Pre-Staged CPA/TPA/PLR/ISL

1. Completely identify and number each component to be tested. A minimum of ten samples is required to be tested for
each of the applicable conditions found in the acceptance criteria. The same samples may be used for various phases
of testing.

2. All components to be tested and their mating parts must be fixtured so that proper alignment is maintained during
testing. Straight-in engagement and extraction are critical to avoid side loads and binding which can affect force
measurements.

3. Engage each component to be tested with its retaining mechanism(s) in place at a rate not to exceed 50 mm/min. Test
TPA, PLR, and ISL forces with terminals installed in all available cavities and test for two mate/unmate cycles.

4. Record the force required to completely engage the component with its mating part and use this value to verify
conformance to the Acceptance Criteria of 5.4.5.2.4.
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B. DISENGAGING FORCE

*** CAUTION ***

The following step may result in sample breakage. Adequate shielding and personnel safeguards must be employed to
ensure the safety of persons and property in the vicinity of the test.

1. With the component fully installed and properly fixtured, disengage the component at a rate not to exceed 50 mm/min.
The force must be applied parallel to the centerline of the component being tested to avoid side loads and binding which
can affect force measurements. The direction must be opposite to the direction of normal insertion of the component
part. Test each applicable condition per Table 5.4.5.2.4.

2. Record the force required to disengage the component from its mating part and use this value to verify conformance to
the Acceptance Criteria of 5.4.5.2.4.

3. For TPAs/PLRs/ISLs, with due care engage the component into the fully locked position and repeat steps 1 and 2.

5.4.5.2.4 Acceptance Criteria

Insertion/Retention forces shall conform to Table 5.4.5.2.4.

TABLE 5.4.5.2.4: PRE-STAGED CPA/TPA/PLR AND ISL ASSEMBLY/DISASSEMBLY FORCES

Engagement Removal
Pre-set to lock Lock to pre-set Pre-set to Removed
Device
(N) (N) (N)

CPA • 60 min
Unmated
•
100 min for airbag deployment n/a 30 min
Connector connectors(1)

CPA • 10 min
• 5 min
Mated • 30 max n/a
Connector • Max. per USCAR-25 Table 7.1

• 60 max with terminals installed in all • 60 max - 1st mate

TPA / PLR
available cavities • 18 min - 2nd mate 25 min
or ISL
• 15 min without terminals
(1) Pre-set to lock is 100 N min for air bag initiators mating to USCAR dwg. 999-U-002-1-Z03 or 999-U-002-1-Z04. This
is needed to compensate for the exposed CPA in that design style.

5.4.5.3 Pin Protection Plate (PPP) Blocking/Removal Force

5.4.5.3.1 Purpose

This test is designed to assess whether a pin protection plate (PPP) is able to withstand expected mechanical stresses and
still remain in its intended position. A PPP is shipped in a pre-set position that protects the blades and the first test in this
section evaluates whether the force needed to unintentionally activate the PPP (the blocking force) is great enough to
withstand forces that may be unintentionally applied. The reset force test determines the force to reset a seated PPP to its
initial position and assures the force required is ergonomically appropriate (this test is applicable only to designs that require
manual PPP reset). The force for complete removal from pre-set position on an unmated connector assures the PPP will
not separate from the connector housing in shipping.

5.4.5.3.2 Equipment

• Insertion/retention force tester with peak and hold feature

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5.4.5.3.3 Procedure

A. PPP BLOCKING FORCE

1. Identify and number each component to be tested. A minimum of ten samples is required to be tested for each of the
applicable conditions found in the acceptance criteria. Samples are to be tested without terminals. This applies to inline
connectors; header connectors are expected to have blades present. If blade tips interfere with the force probe, blades
may need to be removed. The same samples may be used for phases A and B of the testing.

2. All components to be tested and their mating parts must be fixtured so that proper alignment is maintained during
testing. Recording forces perpendicular to the connector surface is critical to avoid side loads and binding which can
affect force measurement data.

3. Engage each component to be tested, at a rate not to exceed 50 mm/min. Force to be applied in a centrally distributed
area of the component. Pushing probe size and shape can be customized to assure the PPP has force applied to it
directly. If ribs are present on the PPP (for help in scoop-proofing the design), pushing on the ribs is acceptable. The
TPA from the mating connector may be used if it provides access to a push surface.

4. When the applicable force per the criteria is reached, hold that force for 5 seconds.

5. Record whether the PPP moved from its starting position or stayed in the original position.

B. PPP RESET AND REMOVAL FORCE

*** CAUTION ***

The following step may result in sample breakage. Adequate shielding and personnel safeguards must be employed
to ensure the safety of persons and property in the vicinity of the test.

1. Skip this step and step 2 if PPP has a self-resetting feature. With the PPP in the seated position and test sample properly
fixtured, move the PPP to the pre-staged (shipping) position at a rate not to exceed 50 mm/min. Apply force
perpendicular to the mating surface of the component to avoid side loads and binding which can affect force
measurement data. The direction of force should be opposite the direction of normal seating of the PPP.

2. Record force to reset the PPP. Leave connector in fixture.

3. With the PPP in the pre-set position and test sample properly fixtured, disengage and completely remove the PPP at a
rate not to exceed 50 mm/min. Apply force perpendicular to the mating surface of the component to avoid side loads
and binding.

4. Record the force required to completely remove the PPP from the pre-set position. Note that flexing of the PPP is
expected due to the nature of these components.
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5.4.5.3.4 Acceptance Criteria

Blocking, reset, and removal forces shall meet the values shown in Table 5.4.5.3.4.

TABLE 5.4.5.3.4: PRE-SET, BLOCKING, AND REMOVAL FORCES FOR PPP

Blocking Force Reset Force Complete Removal

Pre-Set to Lock (1) Lock to Pre-Set from Pre-Set
Connector Size (N) (N) (N)
LARGE
15~60
(Female connector face has a 50 min (3) 25 min
Manual reset only (2)
diagonal dimension >35 mm)

SMALL
10~60
(Female connector face has a 25 min (3) 25 min
Manual reset only (2)
diagonal dimension ≤35 mm)
NOTES:

(1) Specific limit for engagement force is not defined, will be determined by allowable mating force/ergonomic
requirements.
(2) Requirement applies to connectors with a manual type reset only. If part under test is the “automatic” reset

type (where female connector pulls PPP back to pre-set position), ensure PPP does not pull out of
connector completely during unmating in 5.1.7 (Connector Cycling). There is no “Lock to Pre-Set”
requirement in this section for automatic resetting connectors.
(3) Customer may specify other tests and criteria with force applied at corners or select points.

5.4.6 Vibration/Mechanical Shock

5.4.6.1 Purpose

This test subjects a connector system to vibration, simulating accelerated exposure to actual vehicle conditions. Vibration
and shock can cause wear of the terminal interfaces, intermittent electrical contact and failure of mechanical components
of the connector system.

Since unsealed connectors are not suitable for use outside the passenger and luggage compartments, they would normally
be tested only to the non-engine/transmission profile (V1). Sealed connectors may be used in applications requiring direct
attachment to the engine/transmission, so they should normally be qualified to the harsher vibration profiles (V2 to V5).

5.4.6.2 Equipment and Set-up

• Vibration table (with environmental chamber for levels V3 and V4)

• Vibration controller

• Accelerometers

Map each table, cube, or head expander combination. For typical mapping procedure set-up, placement of the control
accelerometer will be determined as follows. Other mapping procedures and control locations are acceptable but must be
documented in the test report and must be approved by the Authorized Person.
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Step 1 With the table, cube and or head expander to be used in this test in place, create a map of the vibration equipment
by measuring the equipment resonance in at least 5 places as far apart as practical (see Figure 5.4.6.2). No
additional mounting features or brackets will be on the equipment for this step.

Step 2 Determine the point of lowest resonance. This is defined as the midpoint between the points of lowest measured
resonance.

Step 3 The control accelerometer shall be mounted at the point of lowest resonance.

Set-up requirements:

1. Use tri-axis accelerometer or sequentially rotate single axis accelerometers for the mapping process.

2. The cross-axis resonance must be no greater than 30% of the control resonance. (The on-axis resonance measured in
step 1 must not vary more than 30%.)

3. The mapping procedure used shall be documented in the test report and will include frequency, acceleration, profile
(random or sine sweep), and accelerometer locations.

2 3
1
5 4

Typical table, cube, or Axis of vibration

head expander

FIGURE 5.4.6.2: TYPICAL MAPPING ACCELEROMETER LOCATIONS

5.4.6.3 Procedure

1. CUT must include all applicable wedges (TPAs, PLRs, etc.), seals, etc. Number each mated connector pair. Prepare
each sample by assembling all applicable parts and bundling (with tape, convolute, scroll, etc.) the conductors. Consult
the Authorized Person for details on intended bundling. See Figure 5.4.6.3 for examples of test mounting arrangements.
Mounting position A is for in-line type connectors. Position B is for connectors that will mate to an electrical device.

2. Construct a suitable mounting apparatus using the following design criteria:

a. The mounting apparatus must be constructed and secured to minimize added effects (harmonics, dampening,
resonance, etc.).

b. For In-Line Connectors, mount the mated connector pair directly to the mounting bracket using the connector feature
provided for mounting. See Figure 5.4.6.3A. Do not use a “Fir Tree” or any other type of mounting device. Instead,
the mounting bracket itself must be constructed so as to include a direct mounting feature to mate with the mounting
feature (dovetail) on the mated connector pair.
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c. For Device Connectors, mount the device directly to the mounting bracket. See Figure 5.4.6.3B. Use the normal
device mounting feature(s) used to secure the device in its intended vehicle location. Do not use any intervening
bracket or mounting device. Instead, the mounting bracket must be fabricated to include any cooperating features
necessary to mount the device directly to it.

d. The conductor attachment must be 100 mm ± 10 mm from the rear of the connector body per Figure 5.4.6.3C.

3. Should an application arise that does not lend itself to either situation described above, consult the Authorized Person.
It is his or her responsibility to devise a suitable method for attaching the CUT as directly and firmly as possible to the
mounting bracket consistent with the intended vehicle mounting.

4. Securely attach the conductor bundle ends to the mounting fixture such that there is a 10 mm ± 5 mm sag relative to
the bisecting plane of the attachment points. See Figure 5.4.6.3C.

NOTE: It is vital to secure the conductors to their respective connector housings. Terminals "float" in their cavities and
will wear rapidly if the associated conductors are allowed unrestrained movement relative to the connector
housing. See 5.4.6.3C.

FIGURE 5.4.6.3A AND 5.4.6.3B: VIBRATION MOUNTING POSITIONS

Zipties/zip locks/
plastic straps/
plastic ties

Tape

Clamping w/
protective
media for wires

100 ±10 mm 100 ±10 mm

FIGURE 5.4.6.3C: TYPICAL WIRE ATTACHMENT TEST SET-UP FOR VIBRATION

5. Subject the CUT to mechanical shock per Table 5.4.6.3A in each of the three mutually perpendicular axes. Mechanical
shock and vibration testing may be completed in sequence for each axis before proceeding to the next axis.
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6. Subject the CUT to the appropriate vibration class schedule per Table 5.4.6.3B in each of the three mutually
perpendicular axes. When identified in Table 5.4.6.3B, thermal cycling shall be performed during the entire vibration
cycle. Related to the temperature/vibration profile that the temperature profile in ISO 16750-3 Section 4.1.1 is an
acceptable alternate to the temperature cycle shown in Table 5.4.6.3B. Sine and random profiles shall be run separately
(not concurrently as sine + random profile). Sine Frequency sweep is 1 octave/minute for all sine profiles.

7. Table 5.4.6.3B is repeated until the test is complete.

8. Age the samples for 48 hours at ambient conditions.

9. At the conclusion of the test, measure the CUT/TUT as required per appropriate test sequencing table

TABLE 5.4.6.3A: SCHEDULE FOR SHOCK TESTING

Vibration Shocks Wave Direction Duration Acceleration

Class per Axis Shape (±) (ms) (g)
V1 10 Half Sine Wave Positive 5 to 10 35
V2 10 Half Sine Wave Positive 5 to 10 35
For V3, V4,
V5 only: 1 132 x 6 = 792 Half Sine Wave Positive/Negative 15 25
Perform
Tests 1 and 2 2 3 x 6 = 18 Half Sine Wave Positive/Negative 11 100

TABLE 5.4.6.3B: SCHEDULE FOR VIBRATION DURATION AND TEMPERATURE

Random Total Vibration Time

Vibration Sine Duration Duration for each CUT Chamber Temperature
Class (hours/axis) (hours/axis) (reference) for Thermal Cycling
V1 N/A 8 24 N/A
V2 N/A 8 24 N/A
Tmin per Table 5.1.4.1 with dwell time of
V3 22 22 132 2 hours then transition to Tmax per Table
5.1.4.1 with dwell time of 2 hours
Tmin per Table 5.1.4.1 with dwell time of
V4 32 50 246 2 hours then transition to Tmax per Table
5.1.4.1 with dwell time of 2 hours
V5 N/A 22 66 N/A

NOTES:

1. Prior note deleted

2. Prior note deleted

3. One thermal cycle is approx. 360 minutes.

4. Humidity is not controlled for the vibration testing.

5. The temperature transition rate in the chamber is to be between 3 to 5 °C/min.

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TABLE 5.4.6.3C: VIBRATION SCHEDULES

Level Random Sine

F PSD PSD
(Hz) (m/s2)2/Hz g2/Hz
5.0 0.192 0.00200
12.5 23.8 0.24800
77.5 0.307 0.00320 Vibration schedule at this level does not
V1
145.0 0.192 0.00200 have a sine component.
200.0 1.13 0.01180
230.0 0.031 0.00032
1000.0 0.002 0.00002
g (rms) 17.74 1.81 g

F PSD PSD
(Hz) (m/s2)2/Hz g2/Hz
60.0 0.096 0.00100
V2 Vibration schedule at this level does not
200.0 144 1.50000
have a sine component.
210.0 9.60 0.10000
1200.0 9.60 0.10000
g (rms) 119 12.1 g

F PSD PSD F Accel. Accel.

(Hz) (m/s2)2/Hz g2/Hz (Hz) (m/s2) g
10 10 0.104 100 100 10.2
100 10 0.104 150 150 15.3
V3
300 0.51 0.0051 200 200 20.4
500 20 0.208 240 200 20.4
2000 20 0.208 255 150 15.3
g (rms) 181 18.5 g 440 150 15.3

F PSD PSD F Accel. Accel.

(Hz) (m/s2)2/Hz g2/Hz (Hz) (m/s2) g
10 10 0.104 100 100 10.2
100 10 0.104 150 150 15.3
V4
300 0.51 0.0051 200 300 30.6
500 20 0.208 240 300 30.6
2000 20 0.208 270 100 10.2
g (rms) 181 18.5 g 440 150 15.3

F PSD PSD
(Hz) (m/s2)2/Hz g2/Hz
20 200 2.08
40 200 2.08
Vibration schedule at this level does not
V5 300 0.5 0.005
have a sine component.
800 0.5 0.005
1000 3 0.031
2000 3 0.031
g (rms) 107.3 10.9 g
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TABLE 5.4.6.3D: VIBRATION SCHEDULES - GRAPHIC

Random Sine
Level (PSD in (m/s2)2/Hz versus Frequency in Hz) (Acceleration in m/s2 versus Frequency in Hz)

Vibration schedule at this level does not have a

V1
sine component.

Vibration schedule at this level does not have a

V2
sine component.

V3

V4

Vibration schedule at this level does not have a

V5
sine component.

NOTES:

(1) Sine and random profiles shall be run separately (not concurrently as sine + random profile).

(2) Sine frequency sweep is 1 octave/minute for all sine profiles.

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5.4.6.4 Acceptance Criteria

Verify conformance of CUT/TUT per corresponding measurement section as identified in test sequence.

5.4.7 Connector-to-Connector Audible Click

5.4.7.1 Purpose

Studies show that assembly plant technicians depend on audible and coincident tactile feedback that indicate full seating
of electrical connectors regardless of background noise. This test measures the level of noise generated when two
connectors are mated. Connectors are mated by hand for this test rather than being clamped into a fixture which could
dampen or amplify the sound.

The values shown in this test procedure and Acceptance Criteria are taken from actual plant experience.

5.4.7.2 Equipment

• dB meter

5.4.7.3 Procedure

16 sample pairs are required (two groups of eight). Samples are to be production intent. The connector cavities shall not be
populated with terminals. Include all TPAs, seals, stuffers and auxiliary pieces as applicable.

1. Measure and record the dB (A) level of the ambient sound within the test environment. The ambient noise level must
be between 30 and 50 dB (A).

2. Locate the sound measuring device or microphone 600 mm ± 50 mm from the connector.

3. Mate the connectors in group 1 by hand and measure the dB (A) level of the sound generated as the lock engages. Do
not bias the connectors toward or away from the latch as they are engaged.

4. Repeat steps 1 through 3 using the group 2 connectors, post moisture conditioning. Parts are brought to their practical
limit of moisture content by exposing “dry as molded parts” to 95 to 98% Relative Humidity at 40 °C for 6 hours
(minimum), then completing the test within 30 minutes.

5.4.7.4 Acceptance Criteria

The values measured in this test shall be documented in the test report. These values should be considered for information
only and are used to compare connector designs or to assist in the connector selection/wire harness design process.

5.4.8 Connector Drop Test

5.4.8.1 Purpose

This test evaluates the ability of the connection to withstand impact due to dropping on a hard surface.

5.4.8.2 Equipment

• Ruler

• Concrete surface
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5.4.8.3 Procedure

1. Prepare 18 connector assemblies with all components to be used in the intended application (CPA, TPA, PLR,
lever/slide, etc.). Lock components as applicable in their design intended pre-staged (shipping) position. For harness
type connectors, do not insert leads or terminals.

2. Divide samples into six groups of three samples each for testing X, Y, and Z axis orientation.

3. For each group, drop one sample at a time once and only once onto a horizontal concrete surface from a height of at
least 1 m, orienting the samples in six groups corresponding to the six connector “faces” of a rectangular connector.
Use one group for each orientation shown.

4. Record any damage or movement/separation of components.

5. Verify conformance of each sample connector assembly to the Acceptance Criteria of 5.4.8.4.

5.4.8.4 Acceptance Criteria

1. Samples shall meet the Acceptance Criteria of 5.1.8, Visual Inspection.

2. Components shall not be displaced from their intended Shipping Position.

5.4.9 Cavity Damage Susceptibility

5.4.9.1 Purpose

This test is intended to demonstrate resistance to damage when the connector TPA (or PLR or ISL as applicable) is forcefully
inserted on a connector with one or more terminals in an incomplete (un-seated) position. The cavity and other plastic and
metal parts must subsequently be able to be assembled correctly and retain full function following such an event. This
procedure does not apply to connectors where the TPA is designed to push the terminal into its seated and locked position
or to TPAs that are designed such that their mating direction interferes or is perpendicular with a terminal that is unseated.

5.4.9.2 Equipment

• Force tester

5.4.9.3 Procedure

1. Obtain samples. Samples consist of five connectors with terminal secondary locks in the un-seated position and five
terminated leads for each terminal size in the connector.

2. Randomly select one cavity of each terminal size from each connector sample.

3. Determine the applicable test force to be applied to the secondary lock using this procedure: Add 40 N to the maximum
force measured to seat the TPA/PLR device (with all terminals located properly) per 5.4.5.2.3 A4. The test force shall
be the determined force or 80 N for ≥1.5 nominal size terminals and 60 N for <1.5 terminals whichever is greater. Note
that the force will increase quickly and an automated stop on the machine applying the force will be needed.

4. Partially insert a terminated lead into the selected cavity. The terminal should be inserted until it is just short of locking
into position. While holding the terminal in this position, apply the force determined in step 3 at a rate not to exceed
50 mm/min to the terminal secondary lock in the direction of normal seating. Record whether the TPA traveled to its
normal seated and locked position.

5. Remove the force and seat the terminal in its normal position. Inspect for damage. Seat the secondary lock.

6. Perform a terminal retention test on each terminated lead per 5.4.1.3 B.

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5.4.9.4 Acceptance Criteria

1. When the force in step 4 is fully applied, the TPA must not seat in its final position.

2. Terminal retention must meet the force listed in the far-right column (Post Humidity) of Table 5.4.1.4.

NOTE: Moisture conditioning is not required for this group of samples, the heading of the table applies to a different
test.

3. No damage must be seen in the inspection from step 5.

5.4.10 Terminal/Cavity Polarization Test

5.4.10.1 Purpose

This test is conducted to ensure that the design of the cavity and terminal polarization features will prevent insertion of the
terminal in any incorrect orientation. This procedure is not required for multi-directional (round) or other designs where the
terminal is meant to plug and lock in any (360 degrees) orientation.

NOTE: Mechanical equipment may not simulate the action of an operator to finesse terminals and connectors during
assembly. Therefore, in addition to this procedure, an expert evaluation shall be conducted and documented to
show that it is not reasonably possible to incorrectly assemble terminals to connectors. A summary of the results
shall be included in the test report.

NOTE: Surrogate data may be used to fulfill the requirements of this test. If surrogate data is used, the design of the cavity,
terminal, cable, and all materials (except terminal plating) shall be identical. Other factors such as connector wall
thickness double or single row, etc. may also influence the test outcome. The Responsible Engineer shall determine
the need for individual testing in such cases.

5.4.10.2 Equipment

• Insertion force tester with peak reading feature and fixtures or jigs as necessary

5.4.10.3 Procedure

1. By analyzing the cavity and terminal design, choose the incorrect terminal orientations to be tested. At a minimum, each
incorrect orientation in increments of 90 degrees must be tested. Rectangular designs where improper insertion at
90 degrees from horizontal is clearly not possible do not need to be tested at these positions. It is permissible to test
these designs in 180 degree increments. The Responsible Engineer is the final authority for determining the positions
to be tested.

2. Prepare enough terminated leads to test each orientation selected in step 1 at least ten times. Prepare leads per 5.1.6,
Terminal Sample Preparation, using the largest gage size conductor and insulation thickness applicable to the design.

3. Procure connectors sufficient to test each incorrect orientation determined in step one at least ten times using a fresh
cavity for each test. Use no less than three connectors. Number each connector and each cavity.

4. Secure the connector shell in an appropriate fixture. The fixture shall not distort the natural state, shape, or geometry
of the connector or the terminal cavities

5. Secure the terminal sample in the force tester by gripping the conductor a minimum of 20 mm behind the insulation
grip.

6. Adjust the connector holder and force tester to insert the terminal in one of the “incorrect” orientations chosen in step 1.
Adjust the force tester to insert the terminal straight into the connector.
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7. At a rate not to exceed 50 mm/min, apply a force equaling 1.5 times the maximum force recorded in 5.4.1.3-7
(Terminal-Connector Insertion Force) or 15 N, whichever is greater.

8. Insert the terminal into the cavity until the force determined in step 7 is reached.

9. Record results (terminal seated in cavity, terminal inserted but did not seat and to what approximate depth, terminal did
not enter cavity, etc.).

10. Repeat steps 4 through 9 using fresh terminals and cavities/connectors until all combinations determined in step 2 have
been tested.

11. Complete the visual examination of the terminals and connectors per 5.1.8.

5.4.10.4 Acceptance Criteria

1. Terminals inserted at a force 1.5 times the normal insertion force or 15 N (whichever is greater) in any incorrect
orientation shall not fit or lock into a connector cavity beyond the insulation wings (grips) or cable seal (see
Figure 5.4.10.4).

2. There shall be no visible damage to either the terminal or connector that would prevent subsequent correct insertion
and function following any attempt at incorrect insertion per this procedure.

3. The expert evaluation shall be completed and documented.

NOTE: Where wire buckling and operator sensitivity cause problems in obtaining test repeatability, terminals may be
crimped to a gage pin, solid core wire, or other metal dowel material and used to obtain measurements. Samples
prepared in this manner require additional connector samples.

Insulation grips or seal must

Connector Body
be visible

Mis-plugged terminal

FIGURE 5.4.10.4: MAXIMUM ALLOWABLE INSERTION OF INCORRECTLY PLUGGED TERMINAL

5.4.11 Connector Mounting Feature Mechanical Strength

5.4.11.1 Purpose

This test is designed to test the mechanical strength of clip slots and other designed-in mounting features for electrical
connectors. Such features must withstand mechanical stresses (pulling, pushing, etc.) expected in the vehicle including
vehicle assembly, service and repair without functional damage to the housing.

5.4.11.2 Equipment

• Force tester

• Metal attachment fixture tooled to the dimensions of a typical mating clip slot (see Figure 5.4.11.3A for an example
using the standard 11 mm clip slot)

• Mating connector for the CUT; one non-mounting (mating) connector may be used to test all connectors if not damaged
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5.4.11.3 Procedure

1. Assure correct number of samples are available. Six directions/locations are tested (F1 through F6). A minimum of
30 connectors (five in each direction) must be tested. Use of a new sample for each test is recommended; however,
the same samples may be used for testing various force directions if not damaged. If clip is tested on the connector
under test and passes per 5.4.5.1.4, testing in direction F5 does not need to be performed. If a retainer clip is available,
it typically will be used to reduce sample size and avoid making a custom fixture with a locking feature.

2. Mate connector under test to its mating connector. Secure the mated connector pair to the attachment bracket in the
way intended for use. No additional reinforcement of the connector slot is permitted.

FIGURE 5.4.11.3A: MOUNTING FIXTURE EXAMPLE (NON-LOCKING)

3. Apply a force to the connector at a rate not to exceed 50 mm/min to the non-mounted mating connector in direction F1
until breakage of the mounting feature, release from fixture, or the force specified in the Acceptance Criteria of 5.4.11.4
is reached. Apply the force 5 mm from the edge (rear or side as applicable). Figures 5.4.11.3B and 5.4.11.3C provide
illustrations for typical connectors.

FIGURE 5.4.11.3B: TEST SET-UP (END VIEW)

FIGURE 5.4.11.3C: TEST SET-UP (3D VIEW)

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4. Remove the connector from the fixture.

5. Repeat steps 2 to 4 with four additional connectors.

6. Repeat steps 2 to 5 in the other directions, F2, F3, F4, F5 (if needed), and F6. Each force is designed to be applied 90
degrees apart. (As noted before, if clip is tested on the connector under test and passes per 5.4.5.1.4, testing in direction
F5 does not need to be performed.)

5.4.11.4 Acceptance Criteria

TABLE 5.4.11.4: CLIP SLOT ACCEPTANCE CRITERIA

Direction of Force Clip Slot Width ≤11 mm Clip Slot Width >11 mm
Per Fig. 5.4.11.3 B/C (N) (N)
F1 50 50
F2 50 50
F3 50 50
F4 50 50
F5 * 110 165
F6 50 50
* Typically not tested based on successful pass of 5.4.5.1.

5.4.12 Mechanical Assist Integrity (Connectors with Mechanical Assist Only)

5.4.12.1 Purpose

This test is used to ensure that lever or slide assist features as part of a connector assembly will remain in place and
undamaged during the wiring harness and vehicle assembly process.

5.4.12.2 Equipment:

• Force tester

5.4.12.3 Procedure

1. Prepare a minimum of five sample connectors with levers/slides in their open position. Wires, terminals, TPAs, and
seals are not required.

2. Complete the Visual Examination per 5.1.8

3. Make a fixture that will secure the connectors to be tested without distorting any of the parts. Mating parts may be used
as part of the test fixture.

4. Mount the samples in the fixture.

5. Apply a 100 N force in Direction “F,” as shown in Figure 5.4.12.2, at the rate of 50 mm/min ± 10 mm/min with the lever
or slide in both the open and closed positions. The point of the force application is determined by the Authorized Person
to be that which is most likely to cause failure.

6. Apply a 100 N force in the direction opposite to Direction “F” at the rate of 50 mm/min ± 10 mm/min with the lever or
slide in the open and closed positions.

7. Position the slide or lever in a position approximately half way between the open and closed positions. Apply a 60 N
force in Direction “F,” as shown in Figure 5.4.12.2, at the rate of 50 mm/min ± 10 mm/min.
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8. Position the slide or lever in a position approximately half way between the open and closed positions. Apply a 60 N
force in the direction opposite to Direction “F,” as shown in Figure 5.4.12.2, at the rate of 50 mm/min ± 10 mm/min

9. Complete the Visual Examination per 5.1.8

FIGURE 5.4.12.2 - SIDE FORCE STRENGTH

5.4.12.4 Acceptance Criteria

1. The lever/slide must withstand a 100 N force in the open and closed positions without separation or damage.

2. The lever/slide must withstand a 60 N force in the midpoint position (lever half -way closed) without separation or
damage.

5.4.13 Connector Seal Retention - Unmated Connector

5.4.13.1 Purpose

This test is done to ensure that connector seals will be sufficiently retained during shipping and handling prior to being
mated or assembled.

5.4.13.2 Equipment

• Variable speed motor with rotating table

5.4.13.3 Procedure

NOTE: If the design uses a pre-staged secondary component that interacts or aids in the retention of the connector seal,
then conduct the test with this component in both its pre-staged and final position. If the design uses a loose-piece
secondary component, then conduct the test with and without this component.

1. Prepare ten fully assembled connector samples. Terminals and wires are not required.

2. Properly secure the sample under test per Figure 5.4.13.3 and ensure that only the connector seal is free to move.
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3. Rotate the table at a speed [rpm] to generate a minimum acceleration of 1960 m/s2 [≈200g] for a minimum of 10 seconds.
Direction is optional. Using the equation below, calculate the required RPM.

N = [(sqrt (a/R)) x 60]/(2 x π)

where:

a = acceleration in m/s²

R = the distance [meters] from the center of rotation to the nearest edge of the connector seal
example:

a = 1960 m/s2 and R = 0.2 m  N = [(sqrt (1960 m/s2/0.2 m)) x 60s]/(2 x π) N = 945.33 rpm

4. Record and document [photograph] the position of the connector seal.

FIGURE 5.4.13.3: UNMATED CONNECTOR SEAL RETENTION TEST CONFIGURATION

5.4.13.4 Acceptance Criteria

The connector seal shall be sufficiently retained in design position such that both mating of the connector and the function
of the seal are not diminished.

5.4.14 Connector Seal Retention - Mated Connector

5.4.14.1 Purpose

This test is used to determine that the connector seal will retain during mating and unmating of the connector assembly.

5.4.14.2 Procedure

1. Prepare ten female housings with radial seals and ten complimentary male connectors or mating parts along with
terminals, wires and seals as appropriate for the design.

2. Mate connector to device or mating male connector.

3. Remove connector from the device or mating connector by using the wires when possible or by grasping the connector
housing. Connector shall be fully separated within 1 second.

5.4.14.3 Acceptance Criteria

Seal shall remain on the connector and in its intended position.

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5.4.15 Airbag Inflator Connector Self-Rejection Assessment

5.4.15.1 Purpose

This test determines the self-ejection performance of airbag connectors designed to self-reject if not properly mated. The
self-ejection performance is important in determining an incompletely mated connector can be detected by monitoring for
electrical disconnection. The test procedures apply to 90 degrees (right angle) and 180 degrees (straight) versions. This
specification applies to versions with and without shorting bars.

5.4.15.2 Equipment

• Force tester with rectangular probe (size between 8 mm and 9 mm, round, rectangular, or square). Customer and
supplier may agree on a smaller size only if the available push surface cannot fit the called-for sizes. Any variance must
be noted in the test report.

• Continuity tester (CT)

• Power supply capable of 100 mADC

• Inert igniter pocket with applicable coding ring, as applicable (typically per USCAR 999-U-002-1-Z02) with 2 Ω bridge
resistor. Reuse of this part is allowed so only 1 device is required for the test.

• Retainer as applicable to design (for example, per USCAR 999-U-002-1-Z03 or USCAR 999-U-002-1-Z04)

• Shim with thickness matched to connector under test so the connector is just prevented from locking

5.4.15.3 Procedure

1. Prepare a sample group with a minimum of ten samples for each of four probe positions (40 samples min) with complete
assembled squib connectors. Any conductor size and insulation type applicable to the connector can be used. These
details must be documented in the test report. Number each connector assembly.

2. Determine an applicable shim thickness as shown in Figure 5.4.15.3E so when placed between connector and top
surface of igniter, the shim prevents the connector from locking but comes as close as possible to allowing the connector
to lock. No friction between shim and connector is allowed. Place the shim on the inert inflator as shown in
Figure 5.4.15.3E.

3. Attach continuity test leads to the connector as shown in Figure 5.4.15.3A. The electrical measurement is done through
the inert igniter.

4. Secure the inert inflator in an appropriate fixture. Place, but do not secure, the female connector on the male connector
in the correct mating orientation. Adjust the probe to insert the female connector axially to the male counterpart.
(Straight-in engagement is important to avoid torque loads and torsion, which may affect the force results.)

5. Test per this sequence:

a. Set stop force on force tester to 80 N to avoid damage or compression of sample.

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FIGURE 5.4.15.3A: CIRCUIT FOR MONITORING CONTINUITY

b. Mate the connector at a uniform rate of 50 mm/min ± 10 mm/min in position 1, 2, 3, or 4 as applicable per step e
(see Figure 5.4.15.3B for locations). Continue until the female connector is blocked by male counterpart and shim.

c. Reverse test direction to unmating direction at a rate of ≥300 mm/min until movement of connector stops. Assure
that force probe is not in contact with connector after this step.

d. Record whether the electrical signal indicates disconnected (resistance infinite) or connected (resistance is not
infinite and approximates the value of the bridge resistor). The resistance value itself will be different depending on
shorting clip version and actuation method and does not need to be recorded.

e. Repeat test with probe in positions 2, 3, and 4 per Figure 5.4.15.3B using new samples. Note that additional test
locations have the force applied off-center with ~1 mm of probe contacting the connector body.

f. Repeat above steps for all samples of group.

Area to apply the probe for testing is

marked as 1 through 4, where #1 probe
location is centered on the axis of the
interface as close as possible without
disturbing wires or motion of connector
components (spring, CPA, etc.).

For locations 2, 3, and 4, the probe

overhangs, contacting only 1 mm of the
connector.

FIGURE 5.4.15.3B: SELF REJECTION SET-UP (90 DEGREES AND 180 DEGREES)

5.4.15.4 Acceptance Criteria

Connector shall be disconnected at end of movement by having an infinite resistance reading and visual confirmation

NOTE: The acceptance criteria of this section is not linked with mating force. Forces are measured by the separate relevant
paragraphs. The result of this section is not a resistance value; it it an electrical condition (connect/disconnect).
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5.5 Connector - Electrical Tests

5.5.1 Insulation Resistance

5.5.1.1 Purpose

This test verifies that the electrical resistance between any two cavities in a connector system will be sufficient to prevent
detrimental electrical conductivity (current leakage) between the various circuits passing through that connector system.
This test is typically done after other environmental stress tests to ensure that any contaminants that may have entered the
connector during testing are not sufficient to create an unintended electrical path. This test shall be performed on all
connector types both sealed and unsealed.

5.5.1.2 Equipment

• Megohmmeter

5.5.1.3 Procedure

NOTE: This test is typically used only in conjunction with another test that subjects the connector to the chance of some
form of moisture or other contaminant intrusion. Test the same samples used for the related test. For unsealed
connector pairs, test samples must rest in ambient environment for ≥3 hours prior to measuring insulation resistance
after any prior environmental conditioning. When sealed connectors are to be tested following exposure to moisture
or other contaminants (except in fluid resistance test) it is important that this insulation resistance test be performed
on each sample within 1 hour of concluding the associated test (otherwise, particularly where samples are exposed
to elevated temperatures in the preceding test, any contaminant that might invade the samples may dry to the point
of being undetectable by this insulation resistance test.)

1. If this test is to be performed to check insulation resistance of a new connector housing, prepare cut leads as specified
in 5.1.6.

2. Connect the Megohmmeter, with the power off during set-up, to the bared conductor ends, as illustrated in Figure 5.5.1.3
so that adjacent cavities have opposite polarization. For special applications, the test voltage may be reduced or
increased with the approval of the Authorized Person. Keep power off while the CUT may be touched.

3. Use the megohmmeter to measure the resistance between adjacent terminals: Apply a test voltage of 500 VDC and
allow the meter to stabilize. Test the mated connector assembly for those samples that have been subjected to prior
stress testing. Test both halves of the connector system if applicable.

4. Record the minimum resistance measured and verify conformance to the Acceptance Criteria of 5.5.1.4.

FIGURE 5.5.1.3: METHOD OF CONNECTING LEADS FOR INSULATION RESISTANCE TEST

5. For connectors with shorting bars, take the insulation resistance measurement between the two terminals designed to
be shorted together by the shorting bars (shorting bars “open”).
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5.5.1.4 Acceptance Criteria

The resistance between every combination of two adjacent terminals in the CUT must exceed 100 MΩ at 500 VDC. This
includes terminals that may be separated by one or more vacant terminal cavities.

5.6 Connector Environmental Tests

5.6.1 Thermal Shock

5.6.1.1 Purpose

This test subjects the connector assembly to extreme temperature cycles that cause expansion and contraction of the
various materials used in the connector system. This is intended to produce accelerated wear at the terminal interface.

5.6.1.2 Equipment

• Two temperature chambers: Cold soak chamber capable of -40 °C and hot soak chamber capable of meeting maximum
temperature of the temperature class selected from Table 5.1.4.1

5.6.1.3 Procedure

1. Number each mated connector pair.

2. Determine the temperature class for the intended application of the connector system from Table 5.1.4.1. Set the cold
soak chamber temperature to the minimum ambient temperature for that class. Set the hot soak chamber to the
maximum ambient temperature for the temperature class selected. Allow the chambers to stabilize.

3. Place the samples in the cold soak chamber so that there is no substantial obstruction to air flow across and around
the samples and the samples are not touching each other.

4. Allow the samples to cold soak for 30 minutes.

5. Transfer samples from the cold to hot chamber in less than 30 seconds. (Automated equipment that moves CUT from
cold to hot chambers is acceptable.)

6. Allow the samples to heat soak for 30 minutes.

7. Transfer the samples from the hot soak chamber to the cold soak chamber.

8. Repeat steps 4, 5, 6, and 7 99 more times.

5.6.1.4 Acceptance Criteria

Verify conformance of CUT/TUT per corresponding measurement section as identified in 5.9 Test Sequence.

5.6.2 Temperature/Humidity Cycling

5.6.2.1 Purpose

This test simulates actual operating conditions using temperature and humidity variations as aging mechanisms for
evaluation of a connector system's electrical durability. High humidity and temperature can promote galvanic and electrolytic
corrosion of the terminals which may cause electrical and mechanical degradation. Temperature cycling promotes relative
movement of the contact surfaces that can cause wear and fretting corrosion. Certain plastic materials may also degrade.
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5.6.2.2 Equipment

• Temperature chamber(s) capable of -40 °C to temperature class selected from Table 5.1.4.1 and RH of 0 to 95%

5.6.2.3 Procedure

1. CUT must include all applicable wedges (TPAs, PLRs, etc.), Seals, etc. Number each mated connector pair.

2. Place the samples in the chamber so that there is no substantial obstruction to air flow across and around the samples,
and the samples are not touching each other.

3. Determine the temperature class for the intended application of the connector system from Table 5.1.4.1. Then set the
Temperature chamber to the temperature for that class. Allow the chamber to stabilize before proceeding.

4. Subject samples to 40 times per the blue-shaded cycling schedule shown in Figure 5.6.2.3. Extended transition times
may be used as long as the dwell times at temperature are maintained. The cycle begins with the sample at -40 °C and
un-controlled relative humidity. Completion of the schedule shown in Figure 5.6.2.3 constitutes one cycle. Use the
maximum ambient temperature for hours 5 through 7, as determined from Table 5.1.4.1 in step 6 above.

5. At the conclusion of the test, measure the CUT/TUT as required per appropriate test sequencing table.

Key:
1. -40 °C
2. 80 to 90 °C
3. Test temperature per Table 5.1.4.1 (Class 3 shown for illustration)
4. Relative humidity is uncontrolled. Do not vent chamber at hour 5
5. Use 80 to 100% relative humidity

FIGURE 5.6.2.3: TEMPERATURE/HUMIDITY CYCLING SCHEDULE

5.6.2.4 Acceptance Criteria

Verify conformance of each CUT/TUT per corresponding measurement section as identified in 5.9 Test Sequence.

5.6.3 High Temperature Exposure

5.6.3.1 Purpose

This test evaluates the effects of long-term exposure to elevated temperature on connector assembly components. Thermal
aging may cause changes in metal and plastic materials, including stress relaxation in important flexing members of the
terminal or its connector. These changes may be detrimental to electrical and physical performance.
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5.6.3.2 Equipment

• Temperature chamber(s) -40 °C to + temperature class selected from Table 5.1.4.1.

5.6.3.3 Procedure

1. CUT must include all applicable wedges (TPAs, PLRs, etc.), seals, etc. Number each mated connector pair.

2. Determine the temperature class for the intended application of the connector system from Table 5.1.4.1. Then set the
temperature chamber to the maximum ambient temperature for that class. Allow the chamber to stabilize before
proceeding.

3. Place the samples in the chamber, set to the maximum ambient temperature, so that there is no substantial obstruction
to air flow across and around the samples, and the samples are not touching each other. Leave the samples in the
chamber for 1008 hours.

4. At the conclusion of the test, measure the CUT/TUT as required per appropriate test sequencing table.

5.6.3.4 Acceptance Criteria

Verify conformance of CUT/TUT per corresponding section identified in 5.9 Test Sequence.

5.6.4 Fluid Resistance

5.6.4.1 Purpose

This test evaluates the sealing capability and material compatibility of a sealed connector system when immersed in various
fluids commonly found in and around road vehicles.

This test is to be used for sealed (S2, S2.5, and S3) connector systems only. Since the same materials are commonly used
for numerous connection systems, the use of surrogate data is acceptable for this test. If surrogate data is used, all
references to the original test(s) shall be included in the test report.

5.6.4.2 Equipment

• Laboratory fume hood

• Stainless steel tanks or glass beakers

• Explosion-proof heat chamber

5.6.4.3 Procedure

1. CUT must include all applicable wedges (TPAs, PLRs, etc.), seals, etc. Number each mated connector pair.

2. Completely submerge sample for 30 minutes in fluids, stabilized at the temperatures shown in Table 5.6.4.3. A fresh
sample is to be used for each fluid.
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TABLE 5.6.4.3: FLUID TEST SCHEDULE

Fluid(1) Specification Test Temp (°C)

Gasoline ISO1817, liquid C 23 ± 5
Diesel fuel 90% ISO 1817, Oil No. 3 + 10% p-xylene* 23 ± 5
Engine oil ISO 1817, Oil No. 2 50 ± 3
Ethanol 85% Ethanol + 15% ISO 1817 liquid C* 23 ± 5
Power steering fluid ISO 1817, Oil No. 3 50 ± 3
Automatic transmission fluid Dexron VI (North American specified material) 50 ± 3
Engine coolant 50% ethylene glycol + 50% distilled water* 50 ± 3
Brake fluid DOT 4 or 5 (or latest available fluid) 50 ± 3
Diesel exhaust fluid (DEF) API certified per ISO22241 23 ± 5
* Solutions are determined as percent by volume.
(1) See Appendix E for fluid source list.

3. At the conclusion of the submersion period, remove the sample from the fluid. Do NOT shake off any excess fluid. Use
care not to splash any fluid on unintended surfaces. Leave the samples "wet" and store them in a suitable container or
area at lab ambient temperature for 7 days. Do not allow samples submersed in different fluids to touch each other and
do not allow any dissimilar fluid drippings to intermingle.

4. At the conclusion of the storage period, samples may be dried sufficiently to allow inspection and to avoid contamination
of test apparatus.

5. At the conclusion of the test, measure the CUT/TUT as required per appropriate test sequencing table.

5.6.4.4 Acceptance Criteria

Verify conformance of CUT/TUT per corresponding measurement section as identified in 5.9 Test Sequence.

5.6.5 Submersion

This test is to be used for sealed (S2, S2.5, and S3 sealing classification) connector systems.

5.6.5.1 Purpose

This test is an accelerated simulation of the "breathing" that may occur in a sealed connector system when it is heated and
suddenly cooled by submersion in a cooler liquid. Salt water is used as the liquid to facilitate detection of any leakage into
the connector. As a further aid to detecting any leakage, it is recommended that a suitable ultraviolet dye be added to the
salt water solution.

5.6.5.2 Equipment

• Stainless steel tanks or glass beakers

• Megohmmeter

• Temperature chamber (-40 °C to + temperature class selected from Table 5.1.4.1)

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5.6.5.3 Procedure

This test is intended for Test Sequences S, RSAA, T, and TUAB (5.9.7) for full validations. For submersion-standalone use
Test Sequence AC (5.9.9).

1. CUT must include all applicable wedges (TPAs, PLRs, seals, etc.). Number each mated connector pair.

2. Prepare enough salt water solution to completely submerse the samples. Use tap water and 15 to 16 g of table salt and
10 mL of liquid dish washing soap per liter. Mix well before adding to test apparatus. It is recommended that an
appropriate ultraviolet dye be added to assist in visual inspection for any ingress of solution into the test samples. Cool
the solution to 0 °C.

3. Place the samples in the chamber such that there is no substantial obstruction to air flow across and around the
samples, and the samples are not touching each other.

4. Determine the temperature class of the connector system from Table 5.1.4.1 and set the chamber to the maximum
ambient temperature for that class. Allow the chamber to stabilize before proceeding. Heat soak the samples at the
elevated temperature of the chamber for 2 hours. If the internal temperature of a representative sample of the parts to
be tested can be shown to stabilize at oven temperature in less than 2 hours, the shorter time may be used. The
demonstration sample may not be used as an actual test sample.

5. Remove the samples from the chamber. Within 30 seconds, submerse them in the 0 °C temperature salt water solution
to a depth of 30 to 40 cm. The samples shall remain submersed at this depth for a period of 30 minutes.

6. At the end of the 30 minute submersion, remove the samples from the salt water solution, shake off the excess solution,
and then carefully dry the exterior surfaces of the samples. Immediately perform the insulation resistance test of 5.5.1
on each sample.

7. For Test Sequence AC (5.9.9), repeat steps 3, 4, 5, and 6 four more times. For Test Sequences R, RSAA, U, and TUAB
(5.9.7), see Test Sequence.

8. At the conclusion of the test, measure the CUT/TUT as required per appropriate test sequencing table.

5.6.5.4 Acceptance Criteria

Verify conformance of CUT/TUT per corresponding measurement section as identified in 5.9 Test Sequence.

5.6.6 Pressure/Vacuum Leak

5.6.6.1 Purpose

This test evaluates the sealing capability of sealed (S2, S2.5, and S3 sealing classification) connector systems when
subjected to a specified pressure differential between the inside and outside of the sealed area.

5.6.6.2 Equipment

• Pressure/vacuum source (regulated)

• Pressure/vacuum gage - 48 kPa (7 psig) minimum

• Container (for sample immersion)

• Temperature chamber (from -40 °C to required temperature per the temperature class selected from Table 5.1.4.1)
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5.6.6.3 Procedure

This test is intended for Test Sequences S, RSAA, U, and TUAB (5.9.7) for full validations. For pressure vacuum leak
standalone, use Test Sequence W (5.9.9).

1. CUT must include all applicable wedges (TPAs, PLRs, seals, etc.). Number each mated connector pair.

2. Insert two tubes of sufficient diameter and wall strength to ensure that there is no possible leak path between the outer
tube surface and the conductor seal into the open cavities in each connector pair. Use of the actual wire leads to replace
the tubes is acceptable if the cable composition is such that sufficient air can pass in a reasonable time to complete the
test. Be sure the tubes are inserted far enough to engage the full sealing capability of the conductor seal. Alternative
methods of adding pressure/vacuum ports are acceptable as long as the integrity of the part is not compromised. The
length and inner diameter of the Pressure/Vacuum supply tubing (or stranded cable if used) as well as the volume within
a mated connector can have an effect on the time required to reach the pressure/vacuum values within the CUT. Two
tubes are inserted so that the pressure/vacuum within the mated connector housing can be monitored to determine if
and when the pressure/vacuum reaches the specified value.

3. Prepare enough salt water solution to completely submerse the samples. Use tap water and 15 to 16 g of table salt and
10 mL of liquid dish washing soap per liter. Mix well before adding to test apparatus. It is recommended that an
appropriate ultraviolet dye be added to assist in visual inspection for any ingress of solution into the test samples.

4. Bend all conductors in the same direction, 90 degrees to the back of each sample connector half and secure them in
this position using actual conductor dress shields if available. This is to simulate dressing of the conductors as they exit
the connector and is intended to stress the conductor seal(s) as in actual applications. If actual production dress shields
are not available, simulate allowable worst-case production application intent as closely as possible. Ensure that the
tube is not kinked, squeezed shut or otherwise obstructed. The tube should be left out of the 90-degree bend if feasible.
Seal all loose conductor ends to eliminate possible leakage through the conductor strands.

5. Connect the free end of one of the tubes (wires) to a regulated pressure source and the other to the pressure/vacuum
gage. Completely submerse all samples into a container of the room temperature bath prepared in step 3.

6. Slowly increase the air pressure of the regulated pressure source supplying the tube (wire) in each sample until the
monitored pressure within the CUT reads 48 kPa (7 psig). Upon the CUT reaching the specified pressure, observe
samples for a minimum of 15 seconds and verify that there are no air bubbles. Note the monitoring requirements outlined
in step 2.

7. Switch the regulated source from pressure to vacuum. Decrease the air pressure until the monitored pressure within
the CUT reads negative 48 kPa (7 psig) and hold for a minimum of 15 seconds. Note the monitoring requirements
outlined in step 2.

8. Remove the samples from the water, shake off excess fluid and then carefully dry all exterior surfaces of the sample.
Immediately perform the insulation resistance test of 5.5.1.

9. For Test Sequences Test Sequences S, RSAA, T, or TUAB (5.9.7), see Test Sequence for appropriate conditioning
then proceed to step 12. For Test Sequence W (5.9.9), proceed to next step.

10. Place the samples in a temperature chamber stabilized at the maximum ambient temperature for the temperature class
selected from Table 5.1.4.1 for the CUT. Heat soak all samples for 70 hours. After the heat soak, remove the samples
from the chamber and allow the samples to cool to room temperature.

11. Repeat steps 4 to 9 except limit pressure in step 6 and the vacuum in step 7 to 28 kPa (4 psig).

12. At the conclusion of the test, measure the CUT/TUT as required per appropriate test sequencing table.
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5.6.6.4 Acceptance Criteria

1. Upon reaching the specified positive internal pressure and holding for 15 seconds, there shall be no bubbles visible
exiting any test sample.

2. Verify conformance of CUT/TUT per corresponding measurement section as identified in 5.9 Test Sequence.

5.6.7 High Pressure Spray

NOTE: The high pressure spray test, when performed at level S3, aligns to ISO 20653 with an IPX9K degree of protection.

5.6.7.1 Purpose

The purpose of this test is to determine the ability of sealed connection systems to withstand high pressure spray. Such
conditions may be encountered where there is direct road splash or where high pressure washing may be expected. Perform
this test for sealed class S2.5 and S3 connectors (see 5.1.4.2). This test is used for Test Sequences AA, RSAA, AB, and
TUAB (5.9.7) for full validations and for high pressure spray standalone test sequence AD (5.9.9).

5.6.7.2 Equipment

• High pressure sprayer capable of Figure 5.6.7.3-1 configuration and Table 5.6.7.3-1 specifications

• Heated water 80 °C ± 5 °C

• Fan jet nozzle per Figure 5.6.7.3-2

• Device holder

• Rotating table

5.6.7.3 Procedure

NOTE: The procedure that follows tests to level S2.5 first and then to level S3. Omit steps 4 and 5 if the customer does not
want an S2.5 evaluation to be performed. Omit steps 6, 7, and 8 if customer does not want an S3 evaluation to be
performed.

1. Assure CUT includes all applicable wedges (TPAs, PLRs, seals, etc.). Number each mated connector pair.

2. Using the samples from 5.6.6, PV testing; or if standalone testing, prepare sample per 5.6.6.3-4, mount the connector
under test onto the device holder such that the connector lays flush against the turntable with wires parallel to the table.

3. Position the sprayer at a Position 1 and initiate turntable rotation.

4. With the table rotating, spray the CUT as specified in Table 5.6.7.3-1 for level “S2.5.”

5. Remove samples from the chamber, shake off excess fluid and then carefully dry all exterior surfaces of the sample.
Immediately perform the insulation resistance test of 5.5.1.

6. Position the sprayer at a 0° and initiate turntable rotation (if not already in place on turntable).

7. With the table rotating, spray the CUT as specified in Table 5.6.7.3-1 for level “S3.”

8. Remove samples from the chamber, shake off excess fluid and then carefully dry all exterior surfaces of the sample.
Immediately perform the insulation resistance test of 5.5.1.

9. At the conclusion of the test, measure the CUT/TUT as required per appropriate test sequencing table.
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FIGURE 5.6.7.3-1: SPRAY NOZZLE AND TABLE ARRANGEMENT

TABLE 5.6.7.3-1: SPECIFICATION FOR HIGH PRESSURE SPRAY TESTING

Sealing Spray Water Exposure

Level* Requirements Pressure and Temp Time
Turntable Speed = 5 rpm ± 1 rpm 1900 to 2400 KPa, 30 sec. each at positions 1, 2, 3, and 4
S2.5 Water flow: 14 to 16 L/min 80 °C ± 5 °C per Figure 5.6.7.3-1 (±5 °C)
Turntable Speed = 5 rpm ± 1 rpm 8000 to 10000 KPa, 30 sec. each at positions 1, 2, 3, and 4
S3 Water flow: 14 to 16 L/min 80 °C ± 5 °C per Figure 5.6.7.3-1 (±5 °C)
* Per Table 5.1.4.2.

FIGURE 5.6.7.3-2: HIGH PRESSURE NOZZLE SPRAY RANGE AND DISTANCE

5.6.7.4 Acceptance Criteria

1. Level “S3” requires passing IR test after spray level “S3 is performed.”

2. Level “S2.5” requires passing IR test after spray level “S2.5” is performed.

3. Verify conformance of CUT/TUT per corresponding measurement section as identified in 5.9.

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5.7 Tests for Headers

5.7.1 Header Pin Retention

5.7.1.1 Purpose

The terminal push-out test is used to determine the retention of the male terminal in certain stitched or insert molded Header
Connectors. It may also be used to test the attachment of male pins when staked or soldered directly to circuit boards.
Proper pin retention assures that the terminal will not be displaced by forces associated with normal engagement and
disengagement of the mating connector. These requirements apply to finished devices only and not to “in-process” products
such as pin blocks or other sub-assemblies. The module and/or connector suppliers need to determine at what stage of the
process these requirements will be tested and verified.

5.7.1.2 Equipment

• Insertion/retention force tester with peak reading feature

• Appropriate fixtures to hold the connector

• Collets, mandrels, or jaws to grip the terminal or pin in a longitudinal direction as needed

5.7.1.3 Procedure

Prepare a set of samples per Table 5.4.1.3.1. Samples are to be production intent. For designs where pins are closely
spaced, pins or terminals may need to be selectively removed or cut to allow space for attachment of jaws, collets, or
mandrels. Pins may be shortened if necessary to allow for gripping and fixturing.

1. Moisture condition samples by exposing “dry as molded parts” to 95 to 98% relative humidity at 40 °C for 6 hours, then
immediately complete the retention test.

2. Measurements shall be taken in both directions if possible, i.e., force to push the pin longitudinally through the
connector, and to pull it out as if removing a female plug from the header. Depending on individual design, “pushing” or
“pulling” may be reversed in order to get the proper reading. It may also be appropriate to apply the loads from the back
of the connector on certain designs. Pressure or tension must be applied parallel with the axis of the pin to achieve
accurate results. In the case of headers with bent pins, it may be necessary to cut the pins in the straight section near
the header. If the pins need to be cut prior to taking the force measurement care should be used to avoid affecting the
test result.

3. Secure the connector body to the appropriate fixture.

4. Using the force tester, apply a ramping pressure to the terminal pin. Note and record the maximum force required to
displace the pin a maximum of 0.2 mm, within the plastic housing or board attachment. Repeat for each pin location.
Where resultant damage to the connector housing would affect readings on adjacent cavities, move to an undamaged
pin or use a fresh connector.

5. Using fresh samples as needed, reverse force direction and repeat steps 3 and 4.
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5.7.1.4 Acceptance Criteria

The minimum force required to displace the pin 0.2 mm longitudinally in either direction shall meet the values specified in
Table 5.7.1.4.

TABLE 5.7.1.4: MINIMUM HEADER PIN DISPLACEMENT FORCE

Terminal Family Minimum Displacement Force

<1.2 15 N
≥1.2 50 N

5.8 Severe Duty Tests

Removed: The tests formerly in this section (extreme vibration and high-pressure spray) have been converted to standard
test classes (V3 and S3) so there are no longer any “special tests.” The section heading has been maintained for proper
section numbering and correlation to previous document versions.

5.9 Test Sequence

5.9.1 General Notes on Test Sequence

1. Test sequence is the order in which tests are performed. The sequence should be logical and interrelated in order to
accurately establish the performance characteristics of the component or assembly.

2. Numbers in the body of charts (5.9.3 to 5.9.9) indicate the order in which the tests or conditioning procedures are
performed. Where there are duplicate numbers in the same column, the procedures are performed concurrently.

3. Destructive tests should be performed only on samples that are not intended for use in further test sequences.

4. The dry circuit resistance test (5.3.1) should always be performed before voltage drop if required by the test sequence
and prior to sample movement.

5. Fixtures and test set-ups should be reviewed by the Authorized Person prior to the start of testing.

6. The sequential test tables in 5.9 are base sequences and may be altered according to the Authorized Person's request.
Any alterations to the test sequence shall be noted in the DVP&R.

7. The total number of test samples needed for sequential tests is shown at the top of each column. It is important to note
that, where parallel test paths are shown, a separate set of samples is required for each path. The same set of samples
is never run through one path and then used again for a parallel test path unless specifically required in the test
request/order. Exceptions are noted in each flow chart.
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5.9.2 Test Sequence Chart

The test flow is given in the charts in 5.9.3 through 5.9.9 (listed below). Appendices C and D define which tests are required
for different conditions of incoming parts under test.

1. Terminal Mechanical Test Sequence - 5.9.3

2. Terminal Electrical Test Sequence - 5.9.4

3. Connector System Mechanical Test Sequence - 5.9.5

4. Connector System Electrical Test Sequence - 5.9.6

5. Sealed Connector System Environmental Test Sequence - 5.9.7

6. Unsealed Connector System Environmental Test Sequence - 5.9.8

7. Stand-Alone Sealing Performance Sequence - 5.9.9

5.9.3 Terminal Mechanical Test Sequence

5.9.4 Terminal Electrical Test Sequence

5.9.5 Connector System Mechanical Test Sequence

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TABLES 5.9.3, 5.9.4, AND 5.9.5:

TERMINAL (MECHANICAL AND ELECTRICAL) AND CONNECTOR (MECHANICAL) TEST SEQUENCES

5.9.3 5.9.4 5.9.5

Misc. Component Engage/Disengage

Maximum Current/Current Cycling
Term. - Term. Engage/Disengage

Conn. Seal Retention - Unmated

Term.-Conn. Insertion/Retention
Test Name

Conn. Conn Mating/Unmating

Mounting Feature Mechanical

Conn. Seal Retention - Mated

Terminal/Cavity Polarization

Mechanical Assist Integrity

Terminal Bend Resistance

Polarization Effectiveness

Header Pin Retention

Cavity Damage
Audible Click

Connector

Connector
Strength
Force

Drop
Test Sequence ID A B C D E F G H I J AE K L X Y Z
Sample Size minimum 15/
10 10 10 10(1) 16 15 (2) 3 5 3 10 20 5 10 10
(See individual procedures) 30
Applicable Cable Size Any All All (3) Any - Any Any - Lg Lg - - - - -
5.1 General 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
5.1.7 Connector and/or Terminal Cycling 3
5.1.8 Visual Inspection 2, 4 2, 4 2, 6 2, 4 2, 4 2, 4 2, 4 2, 4 2, 4 2, 4 2,4 2, 4 2, 4 2,4 2,4 2,4
5.2.1 Terminal to Terminal Engage/Disengage 3
5.2.2 Terminal Bend Resistance 3
5.3.1 Dry Circuit Resistance
5.3.3 Maximum Test Current Capability 4
5.3.4 Current Cycling 5
5.4.1 Terminal - Connector Insertion/retention force 3
5.4.2 Mating/Unmating Force (Non-mech. Assist) 3
5.4.3 Mating and Unmating Force (Mech. Assist) 3
5.4.4 Polarization Feature Effectiveness 3
5.4.5 Miscellaneous Component 3
5.4.7 Connector-to-Connector Audible Click 3
5.4.8 Connector Drop Test 3
5.4.9 Cavity Damage 3
5.4.10 Terminal/Cavity Polarization 3
5.7.1 Header Pin Retention 3
5.4.11 Connector Mounting Feature Mechanical 3
5.4.12 Mechanical Assist Integrity 3
5.4.13 Connector Seal Retention - Unmated 3
5.4.14 Connector Seal Retention - Mated Connector 3
NOTES:

(1) Ten samples for each applicable misc. component engage/disengage force test.

(2) Sample size for polarization effectiveness is determined by the procedure.

(3) See individual procedure for appropriate applicable cable size.

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5.9.6 Connector System Electrical Test Sequence

TABLE 5.9.6: CONNECTOR (ELECTRICAL) TEST SEQUENCES

Table 5.9.6

High Temperature
Temp/Humidity
Thermal Shock
Test Name

Exposure
Vibration

Cycling
Test Sequence ID M N O P
Sample Size minimum5 Connector 10 10 10 10
(See individual procedures) Terminal 10 10 10 10
Applicable Cable Size Largest Largest Largest Largest
5.1 General 1 1 1 1
5.1.8 Visual Inspection 2, 8 2, 8 2, 9 2, 8
5.1.7 Connector and/or Terminal Cycling 3 3 3 3
5.1.9 Circuit Continuity Monitoring (3) 5 (4) 5 (4)
5.3.1 Dry Circuit Resistance (3) 4(6), 6(6) 4(6), 6(6) 4 (2, 6), 6 (2, 6) 4(6), 6(6)
5.3.2 Voltage Drop (3) 7 7 7 (2) 7
5.4.1 Terminal-Connector retention force 10 9
5.4.6 Vibration/Mechanical Shock 5 (4)
5.5.1 Insulation Resistance 8 (1,2)
5.6.1 Thermal Shock 5 (4)
5.6.2 Temperature/Humidity Cycling 5
5.6.3 High Temperature Exposure 5
NOTES:

(1) Deleted (previous revisions referred to USCAR-20 which no longer applies).

(2) It is permissible to use separate sample sets for dry circuit resistance, voltage drop, and insulation resistance due to differences
in sample preparation methods.

(3) It is permissible to divide the test samples into two groups. The first group shall be used for dry circuit resistance measurement.
The second group shall be used for voltage drop measurement and circuit continuity monitoring. NOTE: Do not measure dry
circuit resistance on samples monitored for continuity.

(4) Circuit continuity monitoring (5.1.9) is performed during (simultaneously with) the scheduled conditioning per the Test Sequence
step number.

(5) The samples size minimum indicates the minimum number of samples required. More samples may be required in order to test a
fully populated connector and/or per each measurement item (dry circuit resistance, voltage drop, etc.).

(6) Omit dry circuit testing if testing for terminals larger than 2.8 mm.
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5.9.7 Sealed Connector System Environmental Test Sequence

TABLE 5.9.7: SEALED CONNECTOR SYSTEM ENVIRONMENTAL TEST SEQUENCE

5.9.7

PV Leak, Submersion,

PV Leak, Submersion,
High Temp Exposure-

High Temp Exposure-

High Temp Exposure-

High Temp Exposure-

High Press. Spray

High Press. Spray

High Press. Spray

High Press. Spray

Fluid Resistance

Temp/Humidity-

Temp/Humidity-

Temp/Humidity-

Temp/Humidity-
Test Name

Submersion,
Submersion

PV Leak

PV Leak
Test Sequence ID
Q R S AA RSAA T U AB TUAB
Sample Size minimum Conn. 9 10 10 10 10 10 10 10 10
(2)
Term. See Note 1
Applicable Cable Size Sm Sm Sm Sm Sm Sm Sm Sm Sm
5.1 General 1(3) 1 1 1 1 1 1 1 1
5.1.8 Visual Inspection 2, 4 2,8 2,10 2,8 2,16 2,8 2,9 2,8 2,16
5.1.7 Connector and/or
3 3 3 3 3 3 3 3
Terminal Cycling
5.1.9 Circuit Continuity
Monitoring
5.3.1 Dry Circuit Resistance
5.3.2 Voltage Drop
5.4.1 Terminal-Connector
9 11 11 17 9 10 11 17
retention force
5.4.6 Vibration/Mechanical
Shock
5.5.1 Insulation Resistance 4 7(4) 4,6(4) 4,7(4) 9(4) 11(4) 4,6(4) 4 7(4), 9(4) 11(4)
4,6 4,6 4,7
9(4) 8(4) 10(4) 13(4) 15(4) 8(4) 10(4) 13(4) 15(4)
5.6.1 Thermal Shock
5.6.2 Temperature/Humidity
5 6 5 6
Cycling
5.6.3 High Temperature
5 6 5 6
Exposure
5.6.4 Fluid Resistance 3
5.6.5 Submersion 7 10 7 10
5.6.6 Pressure/Vacuum Leak 5, 8 5,8 5,8 5,8
5.6.7 High Pressure Spray 7(5) 9(4,6) 12(5) 14(4,6) 7(5) 9(4,6) 12(5) 14(4,6)
NOTES:

(1) The number of terminals is determined by the number required to fully populate the total number of connector samples.

(2) Connectors with multi-cavity (mat) conductor seals require one additional set of ten CUTs per multi-cavity (mat) conductor
seals sample preparation (5.1.10) making a total of 2 sets required. This applies to all 5.9.7 tests except Test Path Q (fluid
resistance).

(3) Surrogate validations for fluid resistance are allowed using results for an identical material in another connector.

(4) Step is called-out in environmental test procedure. Do not repeat. step is only shown in table for easier understanding of
sequence.

(5) Use S2.5 spray level per Table 5.6.7.3-1. Omit step if customer does not request S2.5 spray level testing.

(6) Use S3 spray level per Table 5.6.7.3-1. Omit step if customer does not request S3 spray level testing.
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5.9.8 Unsealed Connection System Environmental Test Sequence

5.9.9 Stand-Alone Sealing Performance Test Sequence

TABLE 5.9.8: UNSEALED CONNECTION SYSTEM ENVIRONMENTAL TEST SEQUENCE

TABLE 5.9.9: STAND-ALONE SEALING PERFORMANCE TEST SEQUENCE

5.9.8 5.9.9

High Pressure Spray

Test Name

Pressure/Vacuum

Pressure/Vacuum
Temp/Humidity

Standalone for
Cavity Plugs
Submersion
Standalone

Standalone

Standalone
Test Sequence ID V W AC AD AF
Sample Size minimum Connector 10 10 (2) 10 (2) 10 (2) 10 (3)
(See individual procedures) Terminal Note 1 Note 1 Note 1 Note 1 10 (3)
Applicable Cable Size Largest Smallest(2) Smallest(2) Smallest(2) Smallest
5.1 General 1 1 (2) 1 (2) 1 (2) 1 (2)
5.1.8 Visual Inspection 2,7 2,7 2,7 2,7 2,9
5.1.7 Connector and/or Terminal Cycling 3 3 3 3 3
5.1.9 Circuit Continuity Monitoring
5.3.1 Dry Circuit Resistance
5.3.2 Voltage Drop
5.4.1 Terminal-Connector retention force 8
5.4.6 Vibration/Mechanical Shock
5.5.1 Insulation Resistance 4, 6 4, 6 4, 6 4, 6 4, 8
5.6.1 Thermal Shock
5.6.2 Temperature/Humidity Cycling 5
5.6.3 High Temperature Exposure
5.6.4 Fluid Resistance
5.6.5 Submersion 5 6
5.6.6 Pressure/Vacuum Leak 5 5
5.6.7 High Pressure Spray 5 7
NOTES:

(1) The number of terminals is determined by the number required to fully populate the total number of connector samples.

(2) Connectors with multi-cavity (mat) conductor seals require one additional set of ten CUTs per multi-cavity (mat) conductor seals
sample preparation (5.1.10) making a total of two sets required. This applies to all 5.9.7 tests except Test Path Q (fluid
resistance).

(3) Testing of cable plugs for connectors requires one additional set of ten CUTs. Prepare samples fully populated with cavity plugs
except for a minimum of two adjacent terminal cavities populated with terminals with wires for insulation resistance testing.
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APPENDIX A - DEFINITIONS

Acceptance Criteria:

Generally, the final section in each test description. It specifies the minimum requirements that all test samples must
meet during or at the conclusion of that test.

Authorized Person:

One person will be responsible as the final authority for releasing a given part for production and/or for testing that part.
Such person may delegate authority for testing that part, or may retain the authority. The Authorized Person, as used
in this specification, is the person with authority for making the final decision as to any question arising during testing to
this specification or for any deviations from any requirement of this specification. Such Authorized Person is responsible
for documenting any deviation he/she authorizes from this specification. This documentation must be included in the
final test report.

Bulk Resistance:

That part of total connection resistance attributed to the terminal body. Bulk resistance does not include crimp resistance
or interface resistance.

Cross Axis Resonance:

Resonance measured on a vibration set up at right angles to the intentionally induced axis of motion. Example: X or Y
measured resonance when shaker is operating in the Z axis.

Current Leakage:

Refers to current passage between two or more conductors separated by a normally non-conductive medium when
sufficient voltage potential exists between the conductors. By increasing the potential to 500 VDC or more, the current
flow becomes measurable even though at a micro or nanoampere scale. Current leakage measured at a known voltage
is useful in estimating contact air gap and detecting contaminants without specimen disassembly.

Device Connector:

An electrical connector that mates with the electrical interface of a device (e.g., module headlamp, switch, horn, etc.).

Disengage Force:

The force required to disengage a mated pair of contacts (terminals) or a contact and a mating test gage.

Dry Circuit:

Circuit that operates continuously below a level of 20 mV open circuit voltage and 100 mA current limit.

Edgeboard Connector:

A connector system that utilizes the edge of a printed circuit board for an electrical interface.

Engage Force:

The force required to mate a separate pair of contacts (terminals) or a contact and mating test gage.

Female Connector:

The connector that houses the female terminal(s). May also be called female insulator, receptacle, or socket.
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Female Terminal:

The electrical receptacle that receives the male blade, tab, or pin.

Header Connector:

A connector system that utilizes one or more fixed male terminals inserted into a housing. The non-mating ends of the
terminals are usually soldered to a printed circuit board or connect internally to the device. Header connectors may be
molded into a device housing or may be separate housings permanently attached to the device using rivets, welds, heat
stake, pins, or other methods.

In-Line Connector:

A system using male and female terminals, each contained in an appropriate connector housing to electrically connect
conductors.

Insertion Force:

The force required to insert and retain an individual contact (terminal) into its cavity in a connector.

Insulation Resistance:

The resistance measurement in MΩ between two points separated by a dielectric. This measurement is taken by
application of a voltage (specifically a highly regulated, stabilized DC voltage) across the dielectric, measuring the
amount of current flowing through that dielectric (leakage current), and then calculating (using Ohm's Law) a resistance
measurement. This resistance measurement is used to evaluate insulation integrity

Male Connector:

The connector that houses the male terminal(s). May also be called male insulator.

Male Terminal:

The metal blade or pin that inserts into the female terminal.

Mating Force:

The force required to mate male and female connector halves populated with terminals or to completely seat a connector
populated with terminals in a device header or receptacle.

Maximum Current Capability:

The maximum current carrying capability at room temperature of the specific combination of terminal size, conductor
gage, insulation type, etc., as determined in 5.3.3. This value is used to determine test current for the current cycling
test and is not considered to be an application value. The value obtained in the maximum current test must be de-rated
for actual conditions in the expected application.

Mechanical Assist:

A means of minimizing the operator effort required to mate two connector halves or a connector to a header. Typical
means are a bolt, cam, or lever.

Multi-Cavity Seal:

Also known as a “mat” seal. One-piece cable seal at the back of a connector which allows multiple individual wires to
be environmentally sealed at their entry point to the rear of the connector.
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Pin Protection Plate:

A component designed to protect blades from being bent or damaged during shipping and handling. This pre-assembled
component has an initial location close to the blade tips (preset position) and as the female connector is engaged the
PPP will move downward to the base of the blades. Automatic resetting types will have features that pull the PPP back
to the preset position as the female connector is disengaged.

Precious Metal Contacts:

A terminal interface where the electrical contact surfaces are gold, gold alloy, platinum, palladium, or silver.

Retention Force:

The maximum force that can be exerted on an individual contact (terminal) without dislodging it from its proper position
in its connector cavity. This force may have two different values; one with the associated wedge (TPA, PLR, etc.)
installed and a second value without such assistance.

Room Temperature:

23 °C ± 5 °C.

Soak:

Refers to a time period during which the device under test is exposed to stated environmental conditions, such as
temperature, humidity, current flow, etc. This exposure may be for the purpose of conditioning the sample prior to
another test, or may itself form part of a given test.

Sprung:

(Adj.) Describes any portion or component of a motor vehicle that is supported by the suspension system. Sprung
components do not include tires, wheels, hubs, or outboard disc. or drum brake assemblies.

Shorting Bar:

A mechanical device within a connector designed to electrically short two or more circuits together when the connectors
are not mated. Shorting bars may act to overcome the effects of static electricity or to act as a means of detecting
connectors that are disconnected or not fully mated.

Shipping Position:

The orientation of the connector body to its lever. Applicable to mechanical-assist connectors. The shipping position is
agreed-to between supplier and customer.

Steady State:

A condition of environment or current flow that remains stable so that the sample under test changes less than 2 °C in
5 minutes.

Total Connection Resistance:

Electrical resistance of one terminal to terminal interface plus the resistance of the wire to connection grip for each
terminal. For header type connections, only the resistance of the one wire to terminal connection is included. Included
is the “bulk resistance” of the terminal material itself.
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Unmating Force:

The force required to unmate male and female connector halves or a connector from a device header or receptacle.

Un-Sprung:

(Adj) Describes any component of a motor vehicle that is not supported by the suspension system (see sprung).

Voltage Drop:

The difference in potential between two points in an electrical circuit caused by resistance at a specific current. Voltage
drop may be used to calculate resistance when the current value is known: 1 mV/A = 1 mΩ.
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APPENDIX B - ABBREVIATIONS USED

AIAG Automotive Industry Action Group. Contact at AIAG, Box 77000, Detroit, Michigan 48277-0839. Phone
(248) 358-3570. Website www.aiag.org.

CPA Connector position assurance. A lock-on-the-lock that holds the two halves of a connector together or holds
a connector to an electrical device. The CPA is usually an optional device. It prevents accidental release of
the connector lock and serves as an indicator of full connector mating.

CT Continuity tester. A test device composed of a data analyzer and a continuity monitor.

CUT Component under test.

DMM Digital multimeter.

DVP&R Design Verification Plan and Report.

EWCAP Electrical Wiring Component Applications Partnership. One of several sub-groups of USCAR. Has the task
of commonizing electrical components and interfaces. Website: www.uscar.org/guest/teams/10/Electrical-
Wiring-Component-Applications-Partnership/.

FMVSS Federal Motor Vehicle Safety Standard.

GD&T Geometric dimensioning and tolerancing. A method required by the USCAR Companies for representing
dimensions and their tolerances on all part drawings.

ISL Independent secondary lock. A feature to detect, but not correct, partially seated terminals.

mVD Millivolt drop.

PLR Positive latch reinforcement. Also known as a wedge, spacer, or terminal position assurance (TPA) feature.
It is installed or seated after the terminals are inserted into their housing to assure that the terminals are
properly positioned. It either reinforces the primary terminal locking mechanism or provides a separate
redundant terminal lock.

PPAP Production part approval process.

RH Relative humidity.

ROA Rise over ambient (temperature).

TPA Terminal position assurance. See PLR.

TUT Terminal under test. This is the terminal sample selected for measurement (i.e., dry circuit resistance,
voltage drop, continuity, etc.).

USCAR United States Council for Automotive Research LLC. USCAR is a consortium of representatives from Ford,
General Motors, and FCA US LLC that promotes joint research in pre-competitive areas that can strengthen
the US automotive industry. Website: http://www.uscar.org/guest/index.php.
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APPENDIX C - TESTS FOR MOVED TOOLS, ADDITIONAL TOOLS, AND MATERIAL CHANGES

Ford, GM, and FCA US have jointly published a booklet titled “Production Part Approval Process (PPAP),” which is available
through AIAG. Their address can be found in Appendix B. Section II of the PPAP booklet, “When Submission Is Required,”
outlines the agreed-upon conditions necessitating initial or resubmission of production parts for engineering approval. Table
C1 shows the required performance and durability tests for several of the Section II situations.

“X” in the table indicates which tests are to be performed on production parts for each test from the affected tooling.

TABLE C1: TEST SCHEDULE FOR MOVED TOOLS, ADDITIONAL TOOLS, AND MATERIAL CHANGES

New/Capacity
Tool Transfer Tooling Material Change (1)

Cable or Seal
Seal Material
Un-Sealed
Connector

Connector
Terminal (2)
Connector

Connector

or Applied

Plug (3) (4)

Terminal

Terminal

Sealed
Test
Seq. Test Sequence Name
Seal

Seal
ID ( X = tests to be performed)
A Term-Term Engage/Disengage X X X
B Terminal Bend Resistance X X
C Maximum/Current Cycling X
Terminal-Connector
D X X X X X X X(5)
Insertion/Retention
Miscellaneous Component
E X X X X
Engage/Disengage Force
F Audible Click X X
Connector- Connector
G X X X X X
Mating/Unmating
H Polarization Effectiveness X X
I Drop X X
J Cavity Damage X X X
K Header Pin Retention X (8) X (8)
L Mounting Feature Strength X X
M Vibration/Mechanical Shock X (6) X (6)
N Thermal Shock X X (6) X (6)
O Temperature/Humidity Cycle X X (6) X (6)
P High Temperature Exposure X X (6) X (6)
Q Fluid Resistance X X X
R Temp/Humidity - Submersion X (7) X (7)
S Temp/Humidity - PV Leak X (7) X (7)
RSAA Combined R+S+AA
T High Temp Exp.+ Submersion X (7) X (7)
U High Temp Exposure + P/V X (7) X (7)
TUAB Combined T+U+AB
V Temp/Humidity
W P/V Leak (Standalone) X X X X X (4)
X Mechanical Assist Integrity X X
Y Seal Retention - Unmated
Z Seal Retention - Mated
AA Temp/Humidity - HPS X (7)
AB High Temp Exposure - HPS X (7) X (7)
AC Submersion (Standalone)
AD High Pressure Spray (HPS)
AE Terminal/Cavity Polarization X X X
AF Cavity Plug Pressure/Vacuum X (for plug)
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NOTES:

(1) “Material change” for terminal includes: Base material, hardness, plating, process, and/or electrical lubricant. For connector:
Base material/composition. For seal: Base material, properties, or process.

(2) All terminal material changes: perform 5.9.6.

(3) Seal durometer change: perform 5.4.1-A (T/C Insertion) and Test Seq. W - P/V leak (standalone) only.

(4) Seal color change: perform Test Sequence W - P/V leak (standalone) only.

(5) Perform 5.4.1-A (terminal-connector insertion) only.

(6) Material change on a “family” of connectors requires complete re-test per 5.9.6 to 5.9.8 on one of the new parts. (A “family” of
parts uses a common latch, terminal cavity, and sealing system design.)

(7) It is permissible to perform submersion (5.6.5), pressure/vacuum leak (5.6.6), and high-pressure spray (5.6.7) in series. See test
sequence RSAA when conditioning samples to temperature/humidity cycling (5.6.2) and test sequence TUAB when conditioning
samples to high temperature exposure (5.6.3).
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APPENDIX D - TESTS FOR NEW TERMINAL, CONNECTOR, AND SEAL DESIGNS

“X” indicates tests to be performed on production parts for each test from the affected tooling.

TABLE D1: TESTS SCHEDULE FOR NEW TERMINAL OR CONNECTOR DESIGNS

New Connector in
Test New Design for… Existing family (5) New Cable
Seq. Sequence Name Sealed Unsealed New Conn. Seal (or
ID ( X = tests to be performed) Term. Conn. Conn. Sealed Unsealed Polarization Seal Plug)(6)
A Term. - Term. Engage/Disengage X
B Terminal Bend Resistance X
C Current Cycling X
D Term.-Conn. Insertion/Retention X X X X X
E Misc. Component Engage X X X X
F Audible Click X X X X
G Conn. Conn Mating/Unmating X X X X
H Polarization Effectiveness X X X X X
I Drop X X
J Cavity Damage X X X
K Header Pin Retention X X
L Mounting Feature Strength X X
M Vibration/Mechanical Shock X X X
N Thermal Shock X X X
O Temp/Humidity X X X
P High Temp Exposure X X X
Q Fluid Resistance X
R Temp/Humidity - Submersion X (4)
S Temp/Humidity - PV Leak X (4)
RSAA Combined R+S+AA X (4)
T High Temp Exposure - Submersion X (4)
U High Temp Exposure - P/V Leak X (4)
TUAB Combined T+U+AB X (4) X X
V Temp/Humidity
W Pressure/Vacuum (Standalone) X (1) X
X Mechanical Assist Integrity X X
Connector Seal Retention - Unmated
Y X
Connector
Connector Seal Retention - Mated
Z X
Connector
Temp/Humidity - High Pressure
AA X (4)
Spray
High Temp Exposure - High Pressure
AB X (4)
Spray
AC Submersion (Standalone)
AD High Pressure Spray (Standalone)
AE Terminal/Cavity Polarization X X X
AF Cavity Plug Pressure/Vacuum X (for plug)
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NOTES:

(1) For terminals intended for sealed applications only.

(2) Deleted.

(3) Deleted in rev 7.

(4) It is permissible to perform submersion (5.6.5), pressure/vacuum leak (5.6.6), and high pressure spray (5.6.7) in series. See Test
Sequence RSAA when conditioning samples to temperature/humidity cycling (5.6.2) and test sequence TUAB when conditioning
samples to high temperature exposure (5.6.3).

(5) Same connector family refers to a connector having the same terminal and same design concept (including lock) but having
more or fewer terminal cavities than connector under test.

(6) Applies to changes in applied cable seal design, the cable used in the application, and plugs.
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APPENDIX E - SOURCE LIST FOR AUTOMOTIVE FLUIDS USED IN TESTING

TABLE E1: MATERIALS AND SOURCES

Reference Material Supplier

Engine Oil Available in local automotive parts stores, or:
ASTM D471, IRM 902 Oil 1. R. E. Carroll, Inc.
ISO 1817, Oil No. 2 P. O. Box 5806,
Power Steering ASTM D471, IRM 903 Oil Trenton, NJ 08638-0806
ISO 1817, Oil No. 3 Phone: +1 800-257-9365,
http://www.recarroll.com
2. Penreco
4426 East Washington Blvd.
Los Angeles, CA 90023
Phone: +1 888-227-5448
http://www.penreco.com
3. Citgo Petroleum
699 Heights Rd.
Lake Orion, MI 48362
Phone: +1 800-331-4068
http://www.citgo.com
Automatic Trans Fluid Dexron VI Product is available in local automotive parts stores.
Brake Fluid DOT 5 Available in local automotive parts stores.
DEF - API certified Air1® DEF or equivalent Product is available in local automotive parts stores, or:
per ISO 22241 Mansfield Oil Co.,
Monroe, MI USA 48162
www.mansfieldoil.com
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APPENDIX F - DESIGN NOTES - TEMPERATURE AND CURRENT RATING

Terminals surrounded by other terminals will dissipate heat more slowly and have a higher temperature rise with the same
current flow than terminals located on the periphery of a connector.

Regarding maximum current rating: The “Maximum Test Current Capability” (see 5.3.3) test detailed in this document is
only conducted to establish test parameters. The value obtained in this procedure is used to limit the current in the
“1008 hour current cycling test.” Data collected during this test can also be used to compare various terminals tested to the
same specification. This test cannot establish the Maximum Current Capability of a specific terminal application. For specific
applications, several factors other than current load must be considered. All of the following have an effect on the maximum
current load that can be passed through a terminal grip and interface over the life of the vehicle.

• Wire size: Larger wire sizes can sink heat away from a terminal, into the harness and reduce the terminal operating
temperature. The opposite is true for smaller wire sizes.

• Devices: Some devices can create heat while some can sink heat away from an interface. This can have a dramatic
effect on the maximum current capability of a terminal system.

• Terminal location within a connector: Terminals carrying current loads located next to other terminals carrying current
loads can cause hot spots or heat build-up in a localized area within a connector and lead to terminal failure. At a given
current load, terminals located in the corner connector cavities will run cooler than terminals in the center of the field.

• Sealed connectors: Sealed connectors can trap heat and cause terminals to run hotter than the same terminal at the
same load in an unsealed connector.

• Ambient temperature: Terminals running in elevated temperature environments, such as engine compartments will have
lower Maximum Current Capability than the same terminal/wire combination running in lower temperature locations.

Terminals operating at cooler temperatures tend to exhibit less stress relaxation in the contact beams and less degradation
to the coating and plating on their contact surfaces when compared to the same terminals operating at elevated
temperatures. These factors have an effect on the maximum current load over the usable life span of a terminal system.

Care must be taken to ensure that the conductor and insulation selected for the application (or any test) will withstand the
maximum temperature for the class selected without exceeding the conductor manufacturer's maximum temperature
recommendations.
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APPENDIX G - REVISIONS

This specification was approved by USCAR/EWCAP in December 1999. Any revisions since that date have been
incorporated into the specification. Revisions that altered the content of the specification are recorded below:
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DATE SECTION SUMMARY OF CHANGES MADE * NOTES

12/6/99 all Initial Release Signed off by EWCAP team
1999~2012 Revisions 1 through 6. See past-level documents for changes
12/1/2019 3.5 Added MSA-4 product number to the AIAG listing
12/1/2019 4.4 Table Reformatted test default table
12/1/2019 4.5 Table Show as VDC
12/1/2019 5.1.0 Re-word for clarification of how the spec is written
12/1/2019 5.1.10.1 Change name to mat seal testing (was “multicavity”)
12/1/2019 5.1.4.2 Add Sealing class 2.5 - Sealed (with Low Pressure Spray)
Clarify mat seal test to locate specific place for single small wire to be
12/1/2019 5.1.10.3 #2 placed; test identifies designs that are weak in conditions where the Revision letter #13
big wires move the seal
Changed table for consistent wording; S2 and S3 do not reference
12/1/2019 5.1.4.2
specific tests in this general section
12/1/2019 5.2.1 5.2.1 Terminal to Terminal Engage/Disengage Force Revision letter #6
12/1/2019 5.3.1.1 Clarified dry ckt testing is for mated connectors
Remove "For terminals in mated connector housings, omit steps 1 and
12/1/2019 5.3.1.3
5 to 7" since terminals are in mated condition
12/1/2019 5.3.1.4 Changed reference from step 8 to 9
mVD calc: Reduced from two equations to one; eliminated conversion
12/1/2019 5.3.2.3
to mV/A which was not referenced elsewhere.
12/1/2019 5.3.2.3 #6 Reword for clarity
12/1/2019 5.3.2.3 #9 Changed mV drop equation
Move conversion from header to note 3 on 50 mV drop; change
12/1/2019 5.3.2.4 Table criteria for 6.3 mm to 1.8 mΩ in table; clarify “total resistance” to align
with table header
Clarify definition of Steady State Needed in 5.3.3 step #7 (Maximum
12/1/2019 5.3.3 Revision letter #3
Test Current Capability
Added Figure 5.3.3.3-3 to show probe location for current rating;
12/1/2019 5.3.3.3
formerly, Figure 5.3.3.3-1 was used
Changed Figure 5.3.3.3-1 to show probe location for dry circuit before
12/1/2019 5.3.3.3
inserting into a connector
Clarified that samples are re-used for next test and test-to-failure is
12/1/2019 5.3.3.3 #10
performed with additional parts
Add note for new referenced figure specific to inlines and add "(as
12/1/2019 5.3.3.3#7
defined in Appendix)" for clarity
12/1/2019 5.3.4 Add check for voltage drop to current cycling test. Revision letter #15
Rewrite section to make clear that only large wire samples get pushed
12/1/2019 5.4.1.3.A1 to forward stop; move note from table 5.4.1.3.A1 to 5.4.1.3.A1; clarify
cable prep for mat seal samples
30 N value changed to scale with size; insertion force for a terminal to
be scaled to the terminal width; shall not exceed 15 N for terminals
12/1/2019 5.4.1.4 between 0.5 mm and 1.2 mm; 20 N for blade width; remove note on
table (redundant); #3 deleted requirement for cavity walls to be part of
housing since this was moved; noted cavity damage in table header
12/1/2019 5.4.2 Change force to disengage the primary connector lock Revision letter #7
12/1/2019 5.4.2.3 #C2 Add CPA function test with 70 force on release
Rewrite section for clarity. Stop the force tester at 6 N and verify the
12/1/2019 5.4.2.3C1
lock mechanism remains locked as required in the requirements
12/1/2019 5.4.2.4 Re-write the 6-51 N criteria for clarity
Convert requirements to a table: Connector-Connector
12/1/2019 5.4.2.4
Mating/Unmating/Retention/Lock Deflection Forces in table
12/1/2019 5.4.3 Change force to disengage the primary connector lock Revision letter #7
12/1/2019 5.4.3.3 References to USCAR-25 Table 5.1 changed to 4.1 in three places
12/1/2019 5.4.3.3 E2 Add CPA function test with 70 force on release
Clarification on the purpose of the test as well as whether the 70 N
12/1/2019 5.4.3.3 E3 force is maintained during the inspection and attempted
disengagement
12/1/2019 5.4.3.4E4 Change reference from 5.4.3.4-8 to 5.4.3.4-9
12/1/2019 5.4.5.1.4 Add higher force requirement for over 11 mm wide parts
12/1/2019 5.4.5.2.4 Add criteria to Table 5.4.5.2.4 for CPA engagement force Revision letter #11
12/1/2019 5.4.5.2.4 Remove "after two cycles" and replace with 2nd mate cycle in table
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12/1/2019 5.4.5.3 Added Pin Protection Plate (PPP) Blocking/Removal Force

Integrated thermal cycle into existing TABLE 5.4.6.3B and removed
12/1/2019 5.4.6.3 Revision letter #9
from instruction step 6; also eliminated step 11 since it was redundant
Rewrite 5.4.9.3 and 5.4.9.4 for Cavity Damage Susceptibility; add
12/1/2019 5.4.9 Revision letter #1
terminal pull at end of test
12/1/2019 5.4.9.1 Clarify TPA can also mean ISL or PLR
12/1/2019 5.4.11 Connector Mounting Feature Mechanical Strength Revision letter #8
12/1/2019 5.4.11.2 Identify the bracket as being made of metal
12/1/2019 5.4.11.3 Reword section for clarity on how to perform test
12/1/2019 5.4.11.3 #3 Change fixture description to be made of metal
12/1/2019 5.4.11.3-D Removed Figure 5.4.11.3-D (no new information)
12/1/2019 5.4.11.4 Change criteria to tabular format
12/1/2019 5.4.11.4 Change clip slot retention for F5 to 165 N for slot widths >11 mm
12/1/2019 5.4.15 Add test for evaluation of self-rejecting airbag connectors.
Make clear that 500 V is not active when setting up (step 2); rewrite
12/1/2019 5.5.1.3
step 3 for clarity
12/1/2019 5.6.1.2 Clarification to sections 5.6.1.2 and 5.6.1.3 (Thermal shock) Revision letter #12
12/1/2019 5.6.4.3 Rewrite 5.6.4.3 #2 for clarity
12/1/2019 5.6.6.3 Change step number reference to correct typo in step #11
12/1/2019 5.6.7 Add tests for Sealing class 2.5 - Sealed (with Low Pressure Spray)
12/1/2019 5.6.7.3-1 In table, change angles to positions as referenced in figure
12/1/2019 5.6.7.3-2 In figure, change tolerance on angle to 10 degrees
Connector Mounting Feature Mechanical Strength reference changed
12/1/2019 5.7.2
to 5.4.11 from of 5.7.2
Add: Appendices C and D define which tests are required for different
12/1/2019 5.9.2
conditions of incoming parts under test
12/1/2019 5.9.3 Change wire size of sample for test groups N, O, and P. Revision letter #14
12/1/2019 5.9.4 Removed dry circuit from group "C" (incompatible with high current)
12/1/2019 5.9.5 Renumbered test group "D" to fix gap in numbering
12/1/2019 5.9.5 Table 5.9.5editorial: Added “(“ to 5.4.3
12/1/2019 5.9.6 Delete dry circuit testing from terminals >2.8 mm; delete note 1
Align RSAA and TUAB to be similar steps with different treatments;
update to show internal insulation resistance measurements that are
12/1/2019 5.9.7
internal to spray and environmental procedures; update to show two
levels of high-pressure spray (adding S2.5)
12/1/2019 5.9.7 Update quantity of test samples for test path Q
Table 5.9.7: Perform insulation resistance in RSAA before and after
stress; not in interim; added IR steps for S, RSAA, and TUAB; added
12/1/2019 5.9.7
note 4 to explain that IR measurement is called-for in environmental
test procedure and this is for information only
12/1/2019 5.9.8 Table 5.9.8: Added insulation resistance after environmental stress
12/1/2019 5.9.9 Correct sequence typo; revert to revision 5
12/1/2019 Appendix A Update Definitions to add a definition of the “shipping position” Revision letter #4
Add “X” for new materials; add “AF” for seal plug validation; fix prior
12/1/2019 Appendix C
typing errors
Add test group X for new materials; add test group AF for seal plug
12/1/2019 Appendix D
validation; fix prior typing errors
12/1/2019 Appendix E Allow generic DOT brake fluid to be used