0.64mm Unsealed Dual- Row Automotive
Plug Connectors 638392- [ ], 638393- [ ],
638394- [ ], 638397- [ ], and 1326034- [ ]
Connector Position Assurance
(CPA) Lock in (OPEN) Position
Connector
Locking Latch
Housing
Contact Cavities
(At Wire End of
Plug Connector)
Terminal Position Assurance
(TPA) or Rear Secondary
Lock in (OPEN) Position
PART NUMBER
POSITION
1326034--[ ]
4
638392--[ ]
8
638393--[ ]
10
638394--[ ]
12
638397--[ ]
18
Figure 1
1. INTRODUCTION
0.64mm unsealed dual--row automotive plug
connectors listed in Figure 1 accept Contacts
1326028--[ ] (gold plated) and 638551--[ ] (tin plated)
and mate with printed circuit (pc) board mounted or
free--hanging connectors. These instructions cover
assembly (inserting the contacts into the housing and
mating the connectors) and disassembly (unmating
the connectors and extracting the contacts from the
housing) procedures.
A flat blade screwdriver with a tip having a width
between 1.2 and 1.4 mm is required for insertion and
extraction of the contacts.
NOTE
i
Dimensions in this instruction sheet are in metric
units. Figures are not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 6, REVISION SUMMARY.
408-- 8690
17 DEC 10 Rev A
inserted into the housing, the contact deflects the
housing retention finger, locking the contact into
place. After all contacts are inserted, the TPA lock is
used to ensure that the contacts are fully seated and
to provide additional contact retention.
When mating connectors, the plug connector locking
latch engages the locking tab of the mating connector
and prevents separation. The CPA lock is used to
ensure that the connectors are fully engaged and
prevent accidental deflection of the locking latch.
The plug connector is shipped with the TPA lock and
CPA lock in the pre--set (OPEN) position. Each lock is
actuated when moved to the final--lock (CLOSED)
position.
3. ASSEMBLY PROCEDURE
3.1. Inserting Contacts
The following procedure assumes that the contacts
have been properly crimped. For detailed inspection
requirements, refer to Application Specification
114--13006. Proceed as follows:
1. If the rear secondary lock of the plug connector
is not in the OPEN position, move the rear
secondary lock to the OPEN position (as described
in Paragraph 4.2, Step 2).
2. Grasp the wire of the terminated contact
approximately 19 mm behind the contact insulation
barrel. Align the contact with the desired contact
cavity at the wire end of the plug connector,
orienting the contact so that the retention window
is facing the straight edge of the contact cavity.
See Figure 2. Push the contact straight into the
contact cavity until it bottoms (there will be an
audible “click”).
Wire End of
Plug Connector
Insulation
Barrel
2. DESCRIPTION
The plug connector features a housing with a
connector locking latch, a TPA (or rear secondary)
lock, and a CPA lock. Refer to Figure 1.
Instruction Sheet
Wire
The housing contact cavities are polarized to prevent
the contacts from being inserted upside--down. When
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111
E2010 Tyco Electronics Corporation, Berwyn, PA
PRODUCT INFORMATION 1-- 800-- 522-- 6752
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products names, logos, or company names might be trademarks of their respective owners.
Rear Secondary
Lock in OPEN
Position
Contact
Cavity
Contact Retention Window
Facing Straight Edge of
Contact Cavity
Retention Window
Figure 2
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
1 of 4
LOC B
408- 8690
0.64mm Unsealed Dual- Row Automotive Plug Connectors
CAUTION
!
DO NOT force the contact into the contact cavity.
If there is resistance, pull the contact out, ensure
proper orientation, and re--insert the contact.
3. Lightly pull back on the wire to ensure that the
contact has engaged the housing retention finger.
4. After all contacts are inserted, push the rear
secondary lock into the housing until the lock is in
the CLOSED position. The rear secondary lock is
in the CLOSED position when it is flush with the
housing and the four latches engage the housing.
Check to make sure that each latch is seated
against the housing, and that there is no gap
between the latch and the housing. See Figure 3.
If the rear secondary lock does not fully close,
move the lock to the OPEN position, ensure that
all contacts are fully seated, then try again.
DO NOT force the rear secondary lock to close.
NOTE
i
Proceed as follows:
1. Align the connector locking latch of the plug
connector with the locking tab of the mating
connector. Refer to Figure 4, Detail A.
2. Push the plug connector into the mating
connector, making sure that the key enters the
keying slot, until the connector locking latch and
locking tab engage (there will be an audible “click”).
See Figure 4, Detail B.
Note: Mating Connector is Shown Board Mounted,
Requirements Equally Apply to Free-- Hanging Connector
Detail A
Connector
Locking Latch
Locking
Tab
PC Board
(Ref)
3.2. Mating Connectors
For board mounted applications, the following
procedure assumes that the mating connector is
properly installed onto the pc board.
Key of Plug
Connector
Keying Slot of
Mating Connector
Detail B
Latch Seated
Against Housing
(No Gap)
Rear Secondary
Lock in CLOSED
Position
Lock Flush with Housing
Connector Locking
Latch and Locking
Tab Engaged
CPA Lock in
OPEN Position
Gap Between
Latch and Housing
Latch Not
Seated
Connectors
Fully Mated
Detail C
Latches Seated for Retaining Contacts
(CLOSED Position)
Housing
Housing
CPA Lock in
CLOSED Position
Latch
Latch
Contact Cavities
Latch
Latch
Housing
Housing
Figure 3
2 of 4
Figure 4
Tyco Electronics Corporation
Rev A
408- 8690
0.64mm Unsealed Dual- Row Automotive Plug Connectors
3. Slide the CPA lock of the plug connector toward
the mating connector until it is in the CLOSED
position. The lock is in the CLOSED position when
it is completely over the mating connector. See
Figure 4, Detail C.
CAUTION
!
DO NOT force the CPA lock to close. The lock
will not close unless the connectors are fully
mated.
Tip of Screwdriver
Between Latch
and Housing
Rotate Away from
Contact Cavities
Contact
Cavities
4. DISASSEMBLY
4.1. Unmating Connectors
1. Slide the CPA lock of the plug connector away
from the mating connector until it is in the OPEN
position. The CPA lock is in the OPEN position
when it is no longer over the mating connector (as
shown in Figure 4, Detail B).
CAUTION
!
Contact
Cavities
DO NOT force the CPA lock to open. It may be
necessary to simultaneously push the plug
connector toward the mating connector to relieve
pressure on the lock while sliding the CPA lock to
the OPEN position.
The CPA lock MUST be in the OPEN position
before unmating the connectors.
Rotate Away from
Contact Cavities
Latch
Deflected
2. Depress the connector locking latch of the plug
connector, and pull the plug connector straight
away from the mating connector.
Gap Between
Latch and
Housing
4.2. Removing Contacts
Tip of Screwdriver
Between Latch
and Housing
Latch Not Deflected
(No Gap)
1. Unmate the connectors (as described in
Paragraph 4.1).
2. Insert the tip of the screwdriver between one of
the four latches of rear secondary lock and the
housing, and pivot the screwdriver away from the
contact cavities until the latch is deflected. Repeat
this step for the remaining three latches. See
Figure 5. Check each latch to make sure that there
is a gap between the latch and the housing. Check
to make sure that all of the latches remained
deflected.
3. From the mating face of the plug connector,
insert the tip of the screwdriver behind the side
latch in either side slot of the housing. See Figure
6, Detail A. Slide the side latch until it stops against
the housing. Repeat this step for the side latch in
the side slot at the opposite side of the housing.
The rear secondary lock should be in the OPEN
position (as shown in Figure 6, Detail B).
Rev A
Latches Seated for Removing Contacts
(OPEN Position)
Housing
Housing
Latch
Latch
Latch
Contact Cavities
Latch
Housing
Housing
Tyco Electronics Corporation
Figure 5
3 of 4
408- 8690
0.64mm Unsealed Dual- Row Automotive Plug Connectors
Mating Face of
Plug Connector
Detail A
6. From the mating face of the plug connector,
insert the tip of the screwdriver into the contact
cavity of the contact to be removed. Refer to
Figure 8.
Screwdriver
7. Hold the screwdriver in place, and gently push
the wire of the contact to be removed toward the
housing until it stops (this will relieve the pressure
on the contact retention window).
Slide
8. Pivot the screwdriver toward the other row of
contact cavities to lift the housing retention finger
away from the contact retention window. Refer to
Figure 8. While holding the screwdriver in position,
pull the wire until the contact is removed from the
housing.
Side Latch in Side Slot
of Housing (See Note)
Note: Applies to Both Sides of Housing
Detail B
Housing
Retention Finger
1
Side Latch Against
Housing (See Note)
Mating Face of
Plug Connector
Tip of
Screwdriver
Wire
2
Pivot
Push
Pull
3
Rear Secondary Lock
in OPEN Position
Contact
Cavities
Rear Secondary Lock
(Out of Housing)
Figure 6
4. Push and slide the side latch until it is behind
the housing and releases the rear secondary lock.
Repeat this step for the side latch in the side slot at
the opposite side of the housing. See Figure 7.
5. Pull the rear secondary lock straight out of, and
slightly away from, the housing.
Contact
Retention Window
Figure 8
9. Pull the screwdriver out of the contact cavity.
10. Push the rear secondary lock back into the
housing until it is in the CLOSED position as
described in Paragraph 3.1, Step 4.
5. REPLACEMENT AND REPAIR
Screwdriver
Side Latch Behind
Housing (Applies
to Both Sides of
Housing)
The contacts and housings are not repairable.
Discard and replace any defective or damaged
contacts or connectors. DO NOT re--use a terminated
contact by removing the wire.
6. REVISION SUMMARY
Revisions to this instruction sheet include:
S Updated instruction sheet to corporate
requirements
Pull Rear Secondary Lock Out of,
and Slightly Away From, Housing
Figure 7
4 of 4
Tyco Electronics Corporation
Rev A
