0314043110

MX64 Single Row Sealed Connector Application Specification REV 6 –Jun 14, 2016 Revision History Revision Level Change Information Publication Date Rev 1 9-27-04 Rev 2 11-22-05 Rev 2.11 3-17-06 Rev 2.12 9-9-10 Rev 3 4-28-14 Rev 4 Add TE Gen Y and JST AIT terminal information for series 31404 10-26-15 Rev 5 1. Update TE and Molex terminal information for series 31402/34975 2. Add terminal part number for series 31403/34977 3. Add 8 way assembly information 11-18-15 Rev 6 Add Yazaki FLX 0.64mm and TE 0.64mm Side Orientation terminal for 8 way 6-14-16 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 2 Table of Contents         Section 1: Section 2: Section 3: Section 3A: Section 4: Section 5: Section 5A: Section 6: Product Introduction Product Summary Harness Assembly Instructions 8 Way WDC Assembly Instructions Connector Mating Instructions Service Instructions 8 way WDC Service Instructions Electrical Continuity Checking 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 3 Section 1 Product Introduction 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 4 Section 1: MX 64TM Connectors This reference manual contains information pertaining to the Molex 0.64mm connection system. The connectors mate to various sensors among General Motors, Ford And Daimler Chrysler products There are multiple color coded keying options as defined by USCAR or customer request. In addition there are 3 different terminal options for individual OEM terminal preferences. These preferences are defined by Series Numbers below. Molex Series 31402/34975 = TE/Molex “GET” Molex Series 31403/34977 = Molex MX64 Molex Series 31404 = Yazaki Kaizen 0.64 /Yazaki FLX 0.64 /TE Gen Y 0.64 /TE 0.64 Side Orientation /JST AIT 064 For product ordering information, please contact your Molex Inside Sales Representative at (800)786-6539. 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 5 Section 2 Product Summary 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 6 Section 2: MX 64TM Connectors Single Row Sealed  Connector features –  2, 3, 4, 5, 6, 8 way – – – – – –  Available in circuit sizes Adopted as the new USCAR single row footprint Will accommodate various terminal systems  MX64  Molex or TE GET  Yazaki Kaizen / Yazaki FLX /TE Gen Y /TE Side Orientation /JST AIT 18-22 AWG and .36-.83 mm2 Metric Wire CPA option 4 polarization options Matte seal design Connector housing – Molded circuit pegs can be left in during the Molex assembly process to seal voided circuits  Eliminates separate rear seal cover 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 7 Section 2: MX 64TM Connectors Single Row Sealed_2-6 way TPA Connector Housing Terminal Housing Common Peripheral Seal Common Matte Seal Common CPA 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 8 Section 2: MX 64TM Connectors Single Row Sealed _8 way with wire dress cover Wire Dress Cover (Optional) Connector Housing CPA (Optional) Horizontal Direction Terminal Housing Matte Seal TPA Vertical Direction 0.64mm Connector Application Spec. - REV 6- Perimeter Seal Jun 14, 2016 9 Section 2: MX 64TM Connectors Single Row Sealed  Common connector housing – – – Eliminates separate rear seal cover for the TE /Molex GET, Yazaki /TE /JST AIT or the Molex 0.64 terminal Can accept any terminal housing design Molded circuit pegs can be left in during the Molex assembly process to seal voided circuits.  Allows for customer specific sealing patterns 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 10 Section 2: MX 64TM Connectors Product Identification MOLEX PART NUMBER DATE CODE XX XXX DAY of the year 001 to 365 Note: Product Identification may appear on either side of connector housing. 0.64mm Connector Application Spec. - REV 6- YEAR (last 2 digits) Jun 14, 2016 11 Section 2: MX 64TM Connectors Part # legend single row sealed Female (2-6 way) 3497X-X X X X 3140X-X X X X Seal Cover Configurations 0,1,2,3,4,5,6,7,8,9 CPA OPTION (0,1) 0 = Without CPA 1 = With CPA Polarization Options (1,2,3,4) 1= USCAR Option A (BLACK) 2= USCAR Option B (GRAY) 3= USCAR Option C (BROWN) 4= USCAR Option D (GREEN) 5 = USCAR OPTION B, COLOR: BLACK 6 = USCAR OPTION C, COLOR: BLACK 7 = USCAR OPTION D, COLOR: BLACK Circuit SIZE 2,3,4,5,6,8 Terminal System 2,3,4,5,7 2/5 = TE/Molex "GET" 3/7 = MOLEX 0.64mm 4 = Yazaki Kaizen /TE Gen Y 0.64 /JST AIT 064 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 12 Section 2: MX 64TM Connectors Part # legend single row sealed Female (8 Way) 31404-8 X X X Seal Cover Configurations CPA OPTION (0,1,2,3,4,5,6,7,8,9) 0, 2, 4, 6 OR 8 = Without CPA 1, 3, 5, 7, OR 9 = With CPA Polarization Options (1,2,3,4,5,6,7,8) 1 OR 5 Option A (BLACK) 2 OR 6 Option B (LT. GRAY) 3 OR 7 Option C (DK. GRAY) 4 OR 8 Option D (TBD) Circuit SIZE 8 Terminal System 4: Yazaki Kaizen /Yazaki FLX 0.64 /TE Gen Y 0.64 / TE 0.64 Side Orientation 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 13 Section 2: MX 64TM Connectors Molex MX64 0.64mm TE/Molex “GET” 0.64mm 0.64mm Connector Application Spec. - REV 6- Yazaki Kaizen/Yazaki FLX 0.64 TE Gen Y 0.64/TE 0.64 Side Orientation /JST AIT 0.64mm Jun 14, 2016 14 Section 2: TM Connectors MX 64 TE/Molex GET 0.64mm Female Terminal Series 31402/34975 Terminal Part Numbers Orientation Tab Ford Part Number TE Part Number Molex Part Number 18 & 20 AWG (0.5-0.75mm²) 18 & 20 AWG (0.5-0.75mm²) 18 & 20 AWG (0.5-0.75mm²) TIN TIN TIN # 3F2T-14474-RA # 1393366-1 GOLD # 1L2T-14474-CA GOLD # 1393365-1 22 AWG (0.35mm²) 22 AWG (0.35mm²) TIN TIN # 3F2T-14474-SA GOLD #1L2T-14474-DA # 1393367-1 GOLD # 1393364-1 0.64mm Connector Application Spec. - REV 6- # 342300003 GOLD # N/A 22 AWG (0.35mm²) TIN # 342300001 GOLD # N/A Jun 14, 2016 15 Section 2: MXTE/Molex 64TMGETConnectors 0.64mm Female Terminal Series 31402/34975 Orientation Tab Correct Orientation 90 Misorientation Lock-out 180 Misorientation Lock-out Terminal Insertion Orientation to Grommet Seal Cover 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 16 Section 2: TM Connectors MXMolex 640.64mm Female Terminal Series 31403/34977 Series 31403/34977 Terminal Part Numbers MOLEX Part Number 18 & 20 AWG TIN # 33468-0003 GOLD # 33467-0005 22 AWG TIN # 33468-0001 GOLD # 33467-0003 0.5-0.75mm² TIN # 33468-0024 GOLD # 33467-0024 0.35mm² TIN # 33468-0022 GOLD # 33467-0022 Orientation Tab 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 17 Section 2: TM Connectors MXMolex 640.64mm Female Terminal Series 31403/34977 Orientation Tab Correct Orientation 90°Misorientation Lock-out 180°Misorientation Lock-out Terminal Insertion Orientation to Grommet Seal Cover 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 18 Section 2: TM Connectors MX 64 Yazaki Kaizen/ Yazaki FLX/ TE Gen Y/ TE Side Orientation/ JST AIT 0.64mm Female Terminal Series 31404 Series 31404 Terminal Part Numbers Yazaki Kaizen 0.64mm TE Gen Y 0.64mm JST AIT 0.64mm 18 AWG TIN # 7116-4619-02 GOLD # 7116-4619-08 20 & 22 AWG TIN # 7116-4618-02 GOLD # 7116-4618-08 18 AWG (0.75mm²) 18 AWG (0.75-0.85mm²) TIN # 2035170-2 SILVER # 2035124-2 20 & 22 AWG (0.35-0.5mm²) TIN # SAIT-A02T-M064 GOLD # SAIT-A02GF-M064 20 & 22 AWG (0.3-0.5mm²) TIN # 2035170-1 SILVER # 2035124-1 TIN # SAIT-A03T-M064 GOLD # SAIT-A03GF-M064 Yazaki FLX 0.64mm TE 0.64mm Side Orientation 0.75mm² 18 AWG (0.75mm²) TIN # 7116-7278-02 0.35-0.5mm² SILVER # 2138699-2 20 & 22 AWG (0.35-0.5mm²) TIN # 7116-7277-02 SILVER # 2138699-1 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 19 Section 2: TM Connectors MX 64 Yazaki Kaizen/ Yazaki FLX/ TE Gen Y/ TE Side Orientation/ JST AIT 0.64mm Female Terminal Series 31404 Orientation Tab Correct orientation 90 Misorientation 180 Misorientation Lock-out Lock-out Terminal Insertion Orientation to Grommet Seal Cover 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 20 Section 3 Harness Assembly Instructions 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 21 Section 3: Harness Assembly Instructions A. TPA shown in “As-Shipped” position (FIG. 3-1)   TPA shown “LOCKED” position (FIG. 3-2) TPA to remain in pre-lock position (as shipped) until all circuits are loaded (Fig. 3-1) TPA Fig. 3-1 Fig. 3-2 Section Views of TPA in “Pre-Lock”and “Lock” Positions 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 22 Section 3: Harness Assembly Instructions TPA must be in pre-lock position to install terminals! AS SHIPPED TPA in prelock Fig. 3-3 0.64mm Connector Application Spec. - REV 6- TPA locked Fig. 3-4 Jun 14, 2016 23 Section 3: Harness Assembly Instructions 2-3 way connectors  TPA must be in pre-lock position to install terminals!  If TPA is locked you must move it to the pre-lock position by carefully lifting up on the upper side of the TPA using a 3.5 mm flat blade screw driver. This must be done as shown in FIG. 3-5 DO NOT PRY ON THE LATCH SIDE OF THE CONNECTOR This will damage the TPA and connector!  SCREW DRIVER DO NOT PRY HERE LIFT HERE FIG. 3-5 0.64mm Connector Application Spec. - REV 6- FIG. 3-6 Jun 14, 2016 24 Section 3: Harness Assembly Instructions 4-8 way connectors   TPA must be in pre-lock position to install terminals! If TPA is locked you must move it to the pre-lock position by carefully lifting up on the upper side of the TPA by inserting a 3.5 mm flat blade screw driver into the TPA access window as shown  DO NOT PRY ON THE LATCH SIDE OF THE CONNECTOR .This will damage the TPA and connector! SCREW DRIVER DO NOT PRY HERE LIFT HERE Fig. 3-7 0.64mm Connector Application Spec. - REV 6- Fig. 3-8 Jun 14, 2016 25 Section 3: Harness Assembly Instructions B. 0.64mm Terminal Installation (continued)   With TPA still in pre-lock position, orient terminal to rear of connector. Grip the wire, (Fig. 3-9) and insert through appropriate circuit opening (Fig. 310). If resistance is encountered, retract the terminal and adjust the angle of insertion. Continue inserting the terminal until it stops and locks on the lock finger with an audible click, then pull the wire to ensure terminal is locked. (PUSH CLICK PULL) Fig. 3-9 0.64mm Connector Application Spec. - REV 6- Fig. 3-10 Jun 14, 2016 26 Section 3: Harness Assembly Instructions C. Seating TPA with the 0.64mm Terminal  With the terminals fully installed, the TPA can be seated into its final lock position by applying an even force (Fig. 3-11) until it comes to a stop and you hear an audible click from the locking finger locking in place. If the TPA resists it may be detecting a partially installed terminal. Pull the TPA back into its pre-lock position and make sure all terminals are fully installed. Upon completion, the TPA can be seated. Fig. 3-11 A&B 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 27 Section 3: Harness Assembly Instructions Completed Product 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 28 Section 3A: 8 way Wire Dress Cover assembly Instructions  Wire Dress Cover (WDC) Installation – – – Step1: Bend the wire toward the required direction (Fig.3A-1) Step2: Put the WDR to the position that showed in fig.3A-2 , then Push it to the stopped position along Dir._1 (Fig. 3A-2). Don’t assembly like Fig.3A-5 Step3: Push WDC along Dir._2 to the final lock positon with an audible click (Fig. 3A-3). then slightly pull WDC along Dir._3 to ensure it is locked (Fig.3A-4) Dir._1 Fig. 3A-1 Fig. 3A-2 Dir._3 Dir._2 Fig. 3A-3 Fig. 3A-4 PUSH CLICK PULL WRONG! Fig. 3A-5 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 29 Section 4 Connector Mating Instructions 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 30 Section 4: A.  Connector Mating Instructions Connector polarization options & color identification 2, 3, 4, 5, 6 way USCAR Option A (BLACK) USCAR Option B (GRAY) USCAR Option C (BROWN) USCAR Option D (GREEN)  8 way Option A (BLACK) Option B (LIGHT GREY) Option C (DARK GREY) Special request Option refer to related drawing For updated polarization options consult. HTTP://WWW.USCARTEAMS.ORG 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 31 Section 4: Connector Mating Instructions B. Connector mating  Correctly orient the connector (align keying features) onto the mating connector (Fig. 4-1) Then evenly push the connector onto the mating connector until it locks with an audible click. (Fig. 4-2). Fig. 4-2 Fig. 4-1 Align Keying Features Align Keying Features Mated connector 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 32 Section 4: Connector Mating Instructions C. Optional Connector Position Assurance (CPA)  With the connector mated the CPA can now be engaged. Push the CPA toward the mating surface until it clicks into its locked position (Fig. 4-3). CPA Fig. 4-3 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 33 Section 5 Service Instructions 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 34 Section 5: Service Instructions A. Connector removal from sensor  To un-mate the connector from the sensor, push the CPA (if equipped) away from mating surface (Fig. 5-1) Then depress the latch on the top of the connector so the lock releases.  Grip the connector and evenly pull straight away from the sensor. (Fig. 5-2) Fig. 5-1 Fig. 5-2 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 35 Section 5: Service Instructions B. TPA Servicing  Step 1: To add additional circuits move the TPA from locked to prelock as shown in section 3. Stop pulling when pre-lock is reached.  Step 2: To remove circuits that have been populated you must remove the TPA from the connector by raising it into pre-lock and then continue raising until the TPA has been removed. Fig. 5-3 Step 1: Pry Up TPA 0.64mm Connector Application Spec. - REV 6- Fig. 5-4 Jun 14, 2016 36 Section 5: Service Instructions B. TPA Servicing (continued) TPA Views of TPA in “Pre-Lock” Position 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 37 Section 5: Service Instructions C. 0.64mm Terminal Removal  After removing the TPA, Push up on the wire and carefully displace the locking finger using 1mm blade screwdriver. Once the locking finger has been displaced gently pull on the wire to remove the terminal.  Do not use excessive force. Excessive force can damage the lock finger.  Once the required terminals have been removed, Replace the TPA and lock if terminal population is complete. 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 38 Section 5: Service Instructions D. 0.64mm Terminal Removal (continued)  Do not use excessive force. Excessive force can damage the lock finger.  Deflect the top of locking finger to unlock it from the terminal. Apply light pressure on lock finger while lightly pulling terminal wire. Screw driver Lock Finger Female Terminal Fig. 5-9 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 39 Section 5: Service Instructions E. 0.64mm Terminal Removal (continued)  Carefully displace the locking finger by prying the lock finger up to unlock it from the terminal. Use care not to over deflect the lock finger to avoid damage. Cross sectioned for photographic purpose Insert 1mm pry tool here Unlock finger to remove terminal 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 40 Section 5: Service Instructions F. 0.64mm Terminal Removal (continued)  Once the terminal lock finger is disengaged, pull on the wire (Fig. 512) to release the terminal. Fig. 5-12 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 41 Section 5: Service Instructions G. MX0.64 Terminal Crimping  If the 0.64mm terminal needs to be replaced, a new one can be hand crimped using the Molex Crimp Tool Number 63811-4200. Contact Molex for terminal drawings, hand crimp instructions and crimp height requirements. H. TE/Molex “GET” Terminal Crimping  If the TE/Molex “GET” terminal needs to be replaced, a new one can be hand crimped using the Molex crimp tool number . 638114500 for the wire range: 0.22-0.35 mm2 & 22 awg. And 63811-4600 for the wire range: 0.50-0.75 mm2 & 20-18 awg. Contact Molex for terminal drawings, hand crimp instructions and crimp height requirements. I. Yazaki Kaizen/ Yazaki FLX/ TE Gen Y/ TE Side Orientation/ JST AIT terminal crimping  If the Yazaki Kaizen/ Yazaki FLX/ TE Gen Y/ TE Side Orientation/ JST AIT terminal needs to be replaced please consult Yazaki/TE/JST for crimp tool information. 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 42 Section 5A: 8 way WDC Service Instructions  WDC Removal – Carefully Push down and displace the lock finger using 1.5mm flat blade screw driver. Apply light pressure on lock finger while lightly Push WDC with the thumb (Fig. 5A-4). Once the locking finger has been displaced gently, push the WDC to remove it along Dir._4. (Fig. 5A-6) – Remove the WDC gently along Dir._5. (Fig. 5A-7) – Do not use excessive force. Excessive force can damage the lock finger. (Fig. 5A-5) Dir._4 Dir._5 Lock Finger Fig. 5A-4 Fig. 5A-5 0.64mm Connector Application Spec. - REV 6- Fig. 5A-6 Jun 14, 2016 Fig. 5A-7 43 Section 6 Electrical Continuity Checking 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 44 Section 6: Electrical Continuity Checking A. Pogo Pin Recommendation -MX 0.64mm Terminal  Pogo Pin Specification – See next page. TPA Stop Surface Spherical Tip 0.53 mm 5.75 mm 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 45 Section 6: Electrical Continuity Checking A. Pogo Pin Recommendation - 0.64mm Terminal (continued) Probe Pin Details (0.64mm terminal) Manufacturer: Lone Star Industrial Part number: LS040RS-ELW-277-N-4.7 Pin diameter: 0.020” (0.53 mm) Tip shape: Spherical Tel: (915) 779-7255 LS040RS-ELW-277-N-4.7 POGO PIN 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 46 Section 6: Electrical Continuity Checking B. Recommendations When testing the connector for continuity, it is imperative that you do not damage the terminals! Pogo pins should be checked for damage or sticking several times a shift:  First, a visual inspection of all the pins for damage should be performed.  Next, a testing block should be used to depress all the pogo pins up into the barrel. If there is a bent or sticking pin, it should remain stuck in the barrel of the pogo pin. A damaged or stuck pin should be replaced before any additional testing is performed. 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 47 Section 6: Electrical Continuity Checking B. Recommendations (continued) Probing damage can occur…  If a sharp-ended probe is inserted into the terminal. This may damage the plating and increase contact resistance.  If an oversized diameter probe is inserted into the terminal. This will overstress the beam in the terminal, creating an environment for intermittent contact and/or increased electrical resistance.  If a probe is inserted into the terminal at an angle or off center. This may damage the terminal and/or the connector. 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 48 Section 6: Electrical Continuity Checking C. Manual Probing of the Connector  If the connector must be probed off-line, please use: –  Fig. 6-1 GM probe tool # J-35616-64A for the 0.64mm terminal (Fig. 6-1). Insert the probe through the terminal opening as shown in Fig. 6-2. Fig. 6-2 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 49 Section 6: Electrical Continuity Checking C. Manual Probing of the Connector Manual probing damage can occur…  If a probe is inserted into the back of the connector. This may damage the wire seal, creating an environment for fluid ingress. WRONG!  If the wire insulation is pierced or chafed. This may create a leakpath for fluid ingress and/or wire corrosion. 0.64mm Connector Application Spec. - REV 6- Jun 14, 2016 50