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Performance Specification for Cable-to-Terminal Electrical Crimps
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WiringConnectors and Terminals

IMPORTANT NOTICE: In any intended vehicle application, if theproducts covered by this specification are, or may be, subjected toconditions beyond those described in this document, they must passspecial tests simulating the actual conditions to be encounteredbefore they can be considered acceptable for actual vehicleapplication. Products certified by their supplier as having passedspecific applicable portions of this specification are not to beused in applications where conditions may exceed those for whichthe product has been satisfactorily tested.

The Authorized Person is the final authority as to what testsare to be performed on his or her parts and for what purpose thesetests are required. He or she is also the final authority forresolving any questions related to testing to this specificationand to authorizing any deviations to the equipment or procedurescontained in this specification. Any such deviation must bedocumented and included in the final test report.

1. This specification defines basic test methods andrequirements for solder-less crimped connections. Some sections ofthis document may also be applicable to other terminal attachmentmethods such as sonic or electrical welding or soldering. In thesecases, applicability of the procedures in this document shall bedetermined by the Responsible Engineer.

2. Crimp applications validated to this specification supercedeany crimp information on Ford, GM, or DaimlerChrysler componentprints. The terminal supplier has the primary responsibility fortesting and selection of crimp tooling and to supply detailed crimpinformation or make crimp tooling available to the wiring assemblysupplier actually doing the production crimping. If the wiringsupplier deviates from this information or it is not available,then the responsibility for testing to this specification orgetting approval from the customer with appropriate test datashowing that the crimp will function in it's intended circuitlies with the wiring harness supplier.

3. New or revised terminals shall be designed to meet thisspecification.

4. All new crimp applications shall meet this specification. Newcrimp applications are defined as terminal/wire crimp combinationsnot previously specified on Ford, GM, or DaimlerChrysler vehiclewiring harness assemblies. Existing crimp applications may becarried over if approved by the customer engineeringdepartment.

5. Electrical tests in this specification have been proven bypast experience to ensure that crimps will meet the requirements inSAE/USCAR-2 and SAE/USCAR-20 by including Thermal Shock,Temperature Humidity, and Power Current Cycling. Testing andelectrical acceptance criteria will detect defects in crimp toolinggeometry, plating quality, inadequate strand distribution in thegrip, or cable stranding. Crimp applications that have passedSAE/USCAR-2 and SAE/USCAR-20 normally have only passed the nominalcrimp height and usually only with the largest gauge size.Therefore, crimps within the production crimp height range may notnecessarily pass this test.

6. Procedures included within this specification are intended tocover performance testing and development of electrical terminalcrimps that are part of the electrical connection systems in lowvoltage (0 - 48 VDC) road vehicle applications at ambienttemperatures of 125 C maximum. The OEM customer must approve use ofthese test procedures for use at voltages and temperatures beyondthese limits.

7. These procedures are applicable only to terminals used forin-line, header, edge board, and device connector systems.