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SAE USCAR2-8 2022.pdf
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Performance Specification
for Automotive Electrical Connector Systems
SAE/USCAR-2 REVISION 8
June 2022
ISBN: 978-1-4686-0498-6
__________________________________________________________________________________________________________________________________________
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 © 2022 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
SAE/USCAR-2 REVISION 8
Issued 1997-08
Revised 2022-06
PERFORMANCE SPECIFICATION
FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS
Updates or clarifications may be made as “interim revisions.” Interim revisions are documented as “revision letters” and
are available on the USCAR website at: https://uscar.org
TABLE OF CONTENTS
1.
SCOPE .......................................................................................................................................................... 3
2.
TEST SEQUENCE ........................................................................................................................................ 3
3.
REFERENCED DOCUMENTS ..................................................................................................................... 3
3.1 Document Hierarchy ..................................................................................................................................... 3
3.2 Part Drawing ................................................................................................................................................. 4
3.3 Product Design Specification ........................................................................................................................ 4
3.4 Test Request/Order ....................................................................................................................................... 4
3.4.1 Samples, Test Type, and Special Tests ....................................................................................................... 4
3.4.2 Test Request/Order Instructions ................................................................................................................... 4
3.4.3 Performance and Durability Test Instructions ............................................................................................... 4
3.5 Documents Mentioned in This Specification ................................................................................................. 4
4.
GENERAL REQUIREMENTS ....................................................................................................................... 5
4.1 Record Retention .......................................................................................................................................... 5
4.2 Sample Documentation ................................................................................................................................. 5
4.3 Sample Size .................................................................................................................................................. 5
4.4 Test Conditions and Tolerances ................................................................................................................... 5
4.5 Equipment ..................................................................................................................................................... 6
4.6 Measurement Resolution .............................................................................................................................. 6
4.7 Test Repeatability and Calibration ................................................................................................................ 6
4.8 Conformance Determination ......................................................................................................................... 7
4.9 Disposition of Samples.................................................................................................................................. 7
4.10 Part Endurance ............................................................................................................................................. 7
5.
TEST AND ACCEPTANCE REQUIREMENTS ............................................................................................ 7
5.1 General.......................................................................................................................................................... 7
5.1.1 Performance Requirements .......................................................................................................................... 7
5.1.2 Dimensional Characteristics ......................................................................................................................... 7
5.1.3 Material Characteristics................................................................................................................................. 7
5.1.4 Classifications ............................................................................................................................................... 7
5.1.5 Testing Headers and Direct Connect Components ...................................................................................... 9
5.1.6 Terminal Sample Preparation ..................................................................................................................... 10
5.1.7 Connector and/or Terminal Cycling ............................................................................................................ 10
5.1.8 Visual Inspection ......................................................................................................................................... 11
5.1.9 Circuit Continuity Monitoring ....................................................................................................................... 12
5.1.10 Mat Seal Sample Preparation ..................................................................................................................... 13
SAE/USCAR-2 REVISION 8 Revised 2022-06
PERFORMANCE SPECIFICATION FOR
AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 2 -
5.2 Terminal Mechanical Tests ......................................................................................................................... 14
5.2.1 Terminal to Terminal Engage/Disengage Force ......................................................................................... 14
5.2.2 Terminal Bend Resistance .......................................................................................................................... 15
5.3 Terminal - Electrical Tests........................................................................................................................... 17
5.3.1 Dry Circuit Resistance ................................................................................................................................. 17
5.3.2 Voltage Drop ............................................................................................................................................... 19
5.3.3 Maximum Test Current Capability ............................................................................................................... 21
5.3.4 Current Cycling ........................................................................................................................................... 24
5.4 Connector - Mechanical Tests .................................................................................................................... 26
5.4.1 Terminal - Connector Insertion/Retention and Forward Stop Force ........................................................... 26
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) ........................................................... 32
5.4.4 Polarization Feature Effectiveness ............................................................................................................. 34
5.4.5 Miscellaneous Component Engage/Disengage Force ................................................................................ 35
5.4.6 Vibration/Mechanical Shock ........................................................................................................................ 40
5.4.7 Connector-to-Connector Audible Click ........................................................................................................ 46
5.4.8 Connector Drop Test ................................................................................................................................... 46
5.4.9 Cavity Damage Susceptibility ..................................................................................................................... 47
5.4.10 Terminal/Cavity Polarization Test ............................................................................................................... 48
5.4.11 Connector Mounting Feature Mechanical Strength .................................................................................... 49
5.4.12 Mechanical Assist Integrity (Connectors with Mechanical Assist Only) ...................................................... 51
5.4.13 Connector Seal Retention - Unmated Connector ....................................................................................... 52
5.4.14 Connector Seal Retention - Mated Connector ............................................................................................ 53
5.4.15 Airbag Inflator Connector Self-Rejection Assessment ................................................................................ 53
5.4.16 Bolt-Assembled Connector Function .......................................................................................................... 55
5.5 Connector - Electrical Tests ........................................................................................................................ 58
5.5.1 Insulation Resistance .................................................................................................................................. 58
5.6 Connector Environmental Tests .................................................................................................................. 59
5.6.1 Thermal Shock ............................................................................................................................................ 59
5.6.2 Temperature/Humidity Cycling .................................................................................................................... 60
5.6.3 High Temperature Exposure ....................................................................................................................... 61
5.6.4 Fluid Resistance .......................................................................................................................................... 62
5.6.5 Submersion ................................................................................................................................................. 63
5.6.6 Pressure/Vacuum Leak ............................................................................................................................... 64
5.6.7 High Pressure Spray ................................................................................................................................... 65
5.7 Tests for Headers ........................................................................................................................................ 67
5.7.1 Header Pin Retention .................................................................................................................................. 67
5.8 Severe Duty Tests ....................................................................................................................................... 68
5.9 Test Sequence ............................................................................................................................................ 69
5.9.1 General Notes on Test Sequence ............................................................................................................... 69
5.9.2 Test Sequence Chart .................................................................................................................................. 69
5.9.3 Terminal Mechanical Test Sequence .......................................................................................................... 69
5.9.4 Terminal Electrical Test Sequence ............................................................................................................. 69
5.9.5 Connector System Mechanical Test Sequence .......................................................................................... 69
5.9.6 Connector System Electrical Test Sequence ............................................................................................. 71
5.9.7 Sealed Connector System Environmental Test Sequence ......................................................................... 72
5.9.8 Unsealed Connection System Environmental Test Sequence ................................................................... 73
5.9.9 Stand-Alone Sealing Performance Test Sequence .................................................................................... 73
APPENDIX A DEFINITIONS ............................................................................................................................................. 74
APPENDIX B ABBREVIATIONS USED ............................................................................................................................ 78
APPENDIX C TESTS FOR MOVED TOOLS, ADDITIONAL TOOLS, AND MATERIAL CHANGES ................................ 79
APPENDIX D TESTS FOR NEW TERMINAL, CONNECTOR, AND SEAL DESIGNS ..................................................... 81
APPENDIX E SOURCE LIST FOR AUTOMOTIVE FLUIDS USED IN TESTING ............................................................ 83
APPENDIX F DESIGN NOTES - TEMPERATURE AND CURRENT RATING ................................................................ 84
APPENDIX G REVISIONS ................................................................................................................................................. 85
SAE/USCAR-2 REVISION 8 Revised 2022-06
PERFORMANCE SPECIFICATION FOR
AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 3 -
1. SCOPE
This specification covers performance testing at all phases of development, production, and field analysis of electrical
terminals, connectors, and components that constitute the electrical connection systems in road vehicle applications that
are: low voltage (0 to 20 VDC) or Coaxial. Incomplete (mechanical) specifications for jacketed twisted pair connectors are
also provided. 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 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.
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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