Engineering Specification

ES-BU5T-14A121-AA

PART NAME: PART NUMBER:

SPECIFICATION – WIRING ASSEMBLY AND CABLE ES-BU5T-14A121-AA
INDEX
LET F F F F F F F F h F F F K G G G G G G J G G G
FR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

LET G G G G G G L L H H
FR 24 25 26 27 28 29 30 31 32 33
DATE LET SECT REVISION DR CK PREPARED BY:

7-22-2016 REDRAWN AFTER CHANGE E4 R. W. Reini

08-04-2016 F1 27 REVISED FIGURE 2 AND NOTE RR RR CHECKED BY:

F2 4,20,22 UPDATED SDS REQUIREMENT REFERENCES RR RR R. W. Reini

F3 19 CLARIFIED TAPE SPEC REFERENCE RR RR DETAILED BY:

08-04-2016 AELE-E-12982958-237 (TYPE NAME HERE)

12-13-2016 G1 14 REVISED SECTION 5.2 RR RR REFERENCE:
G2 15 ADDED SECTION 5.3 RR RR (ES-F65B-14A121-AA

12-13-2016 AELE-E-12982958-314
03-30-2017 H1 9 REViSED SECTOR 2.4 RR RR

H2 13 REVISED SECTION 4.4.2, OPTION F RR RR APPROVAL

H3 32-34 ADD APPENDIX A RR RR DESIGN ENG. SUPERVISOR:
H4 23 REVISED SECTION 13.0 RR RR M. C. Brabant
03-30-2017 AELE-E-12982958-403 DESIGN ENG. MANAGER:
08-03-2017 J1 20 REVISED SECTION 9.1 RR RR T. D. DeWitt

08-03-2017 AELE-E-12982958-478 OTHER (AS REQUIRED):

02-16-2018 K1 13 REVISED SECTION 4.4.1 OPTION A RR RR (TYPE NAME HERE)

K2 13 REVISED SECTION 4.4.2 RR RR

02-16-2018 AELE-E-12982958-585
04-04-2018 L1 30-31 REVISED TABLE 1 RR RR
04-04-2018 AELE-E-12982958-621

STANDARD NOTES:
FOR CURRENT RELEASE STATUS, SEE WERS ENGINEERING NOTICE.
CONTROL ITEM –IDENTIFIES CRITICAL CHARACTERISTICS DESIGNATED BY THE CROSS FUNCTIONAL
TEAMS DEVELOPING THE PRODUCT. THESE, AND ADDITIONAL CRITICAL CHARACTERISTICS IDENTIFIED
BY PROCESS REVIEWS, MUST APPEAR ON THE CONTROL PLANS ACCORDING TO ISO/TS 16949. THESE
CONTROL PLANS REQUIRE PRODUCT ENGINEERING APPROVAL.

Global Manufacturing Quality FRAME 1 OF 33

GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331
 Engineering Specification
ES-BU5T-14A121-AA

Section Title Page

1.0 Scope ...................................................................................................................4
2.0 Termination Requirements (Crimping Terminals to Wire) ....................................4
Crimp Specification .........................................................................................4
Application of Terminals .................................................................................4
Termination Quality.........................................................................................5
Tooling Certification ...................................................................................5
Material .......................................................................................................5
Conductor crimp width C.C.W ...................................................................5
Conductor crimp height C.C.H. ...................................................................5
Strip end of insulation..................................................................................5
Wire strand ends ..........................................................................................5
Insulation crimp width I.C.W. .....................................................................6
Insulation crimp height I.C.H. .....................................................................6
Terminal Bend.............................................................................................6
Conductor Crimp Roll .................................................................................7
Fractures......................................................................................................7
Bellmouth (Flare) ........................................................................................7
Cut-off Tab..................................................................................................8
Missing or Broken strands ...........................................................................8
Individual Wire Seal and Mat Seals (Terminal pushed through seal)............8
Pull Testing .................................................................................................8
Cut or pierced insulation ..............................................................................8
Termination Sensors ....................................................................................9
Eyelet Crimp Sealing or Insulating...................................................................9
3.0 Soldering Requirements .......................................................................................9
Dip Soldering...................................................................................................9
Re-flow Soldering .......................................................................................... 10
Spot Soldering ............................................................................................... 10
4.0 Splicing.............................................................................................................. 10
Requirements ................................................................................................. 10
Splice Pull Test .............................................................................................. 10
Splice Peel Testing......................................................................................... 10
Insulation ....................................................................................................... 12
Location......................................................................................................... 13
5.0 Outer Covering................................................................................................... 13
Tape............................................................................................................... 13
Taping to the back of connectors .................................................................... 15
6.0 Molding/Insulation ............................................................................................. 15
Durometer...................................................................................................... 15
Coloring......................................................................................................... 15
Grommet Pull Test ......................................................................................... 16
7.0 Dimensioning and Tolerancing........................................................................... 16
Single Wire .................................................................................................... 16
Multiple Wire ................................................................................................ 16

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GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
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 Engineering Specification
ES-BU5T-14A121-AA

Tape Ties ....................................................................................................... 17

Retainers and Other Components ................................................................... 17
Retainer Pull Force Requirement.................................................................... 16
Wire Harness Neatness .................................................................................. 16
8.0 Section Removed ............................................................................................... 18
9.0 Shielding Composition ....................................................................................... 19
General .......................................................................................................... 19
Shielded Drain Wire ...................................................................................... 20
10.0 Sealed Connectors ............................................................................................ 20
Mat Seals ....................................................................................................... 20
Individual Wire Seals ..................................................................................... 21
Cavity Plugs .................................................................................................. 18
11.0 Terminal Secondary Locks (a.k.a. TPA) ........................................................... 21
Terminal Push-out Testing ............................................................................. 21
12.0 Electrical Requirements.................................................................................... 21
Fixtures Which Contact Terminals ................................................................. 22
Electrical Control/Maintenance Plans............................................................. 22
Diodes ........................................................................................................... 22
Similar Terminals in the Same Connector ...................................................... 23
13.0 Identification .................................................................................................... 23
Label Characteristics ...................................................................................... 23
Printing Method ............................................................................................. 23
Design and Proportions .................................................................................. 24
Single Wire and Rip Cord .............................................................................. 24
14.0 Shipping Requirements .................................................................................... 25
15.0 Black Box Components .................................................................................... 25

Attachments

Fully Taped Bundle Figure 1

Dressed Connector Taping Figure 2
Takeout Dimensioning Figure 3
Cumulative Limit Example Figure 4
Tolerance Example #1 Figure 5
Tolerance Example #2 Figure 6
Cavity Plug Seating Figure 7
Tests that qualify as PV and IP Table 1

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GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331
 Engineering Specification
ES-BU5T-14A121-AA

1.0 Scope

This specification applies to electrical wiring assemblies, cables, and wiring pigtails/flyleads
and details of their construction including wires, terminals, connectors, individual wire
seals, etc., as called out on wiring assembly drawings. This specification supersedes all
previous versions and wiring harness-manufacturing specifications.

This specification outlines the minimum inspection criteria to be utilized in the inspection
process at the harness or pigtail/flylead manufacturing location and other associated facilities.

Ongoing process capability must be demonstrated and documented for all requirements
identified in this specification.

2.0 Termination Requirements (Crimping Terminals to Wire)

2.1 Crimp Specification
All terminal to wire crimps supplied to Ford Motor Company and its affiliates must have
documented compliance to Requirement EL-0038 (RQT-180107-008676) for wires 8
mm2 and less and Requirement EL-0176 (RQT-180107-008728) for wires larger than
8 mm2, both of which reference the USCAR crimp specification (USCAR-21). Testing
must be done using bare wire to optimize the crimp parameters even if a tin plated wire
is used in production. Timing for documenting compliance is at the <PEC> milestone
for GPDS programs.

EL-0038/EL-0176 testing may be referenced from another supplier, such as the

terminal manufacturer, but the documented evidence must identify the crimp tool
geometry, wire construction, and application parameters used to demonstrate
compliance. The terminal to wire crimp process used by the harness manufacturer
must be traceable to that which was validated.

Eyelets where the wires are ultrasonically welded must comply with USCAR-38.

Spot soldering per section 3.7 is allowed as a temporary method for using
terminal/wire applications with crimps that do not pass the electrical resistance
specification of EL-0038. Soldering is expensive and is expected only as a
temporary alternative. For splice clips, see section 4.

Ford Connector group must approve all deviations in writing.

2.2 Application of Terminals

Automatic application of terminals to both single and double terminations is preferred
over bench presses. Use of hand-held crimping tools is forbidden.

Wiring suppliers may determine their own crimp tooling as long as validation is per EL-
0038 or EL-0176. Terminal suppliers must provide crimp validation data, crimp tool
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 Engineering Specification
ES-BU5T-14A121-AA

dimensions and/or crimp tooling used for terminal validation upon request by the Wiring
Supplier to insure Crimp Electrical and Mechanical Capability.

2.3 Termination Quality

Wire harness suppliers must have an approved control plan for their overall crimp
process. This plan must contain “visual crimp standards, measurement methods,
test methods, and frequency of testing” to be used for in-process evaluation.

Each applicator system must be capable of meeting the finished crimp quality
inspection including the following characteristics and others determined by FMEA's:

2.3.1 Tooling Certification

Certify that the proper authorized tooling is being used in each new setup or
tooling change to assure that the correct crimp geometry is achieved and to
comply to crimp validations.

2.3.2 Material
Assure that the proper terminal, seal, and cable is being used for each new setup
or terminal/cable change.

2.3.3 Conductor crimp width C.C.W.

Measure crimp widths at initial setup and after making tooling changes and
compare to requirements from approved wiring supplier or terminal supplier crimp
development table.

2.3.4 Conductor crimp height C.C.H.

Measure crimp height at initial setup, tooling change, material change, and once
each hour. This frequency may be less if capability is demonstrated. C.C.H.
must meet requirements from approved crimp development table. Control of the
C.C.H and tooling is actual method of control for the conductor wire crimping
process. Process capability (including the capability of the measurement method)
must be demonstrated.

2.3.5 Strip end of insulation

The end of the insulation must be visible in the window between the wire crimp wings
and the insulation crimp such that the conductor is visible and should be centralized
as much as possible. In no case may insulation be crimped in the conductor crimp.

2.3.6 Wire strand ends

The end of the conductor must extend beyond the front edge of the conductor crimp.
The projecting end of the conductor must not affect the insertion, locking functions of
the terminal, or mat seals. Conductor length is not to extend past the conductor
crimp by more than 0.5 mm if not otherwise specified by the terminal manufacturer.
Tighter conductor lengths shall be followed when specified on the wire harness print.

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GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331
 Engineering Specification
ES-BU5T-14A121-AA

Exception: For eyelets and battery cable terminals, conductor lengths extending past
the conductor crimps more than 0.5 mm are permissible as long as sealing, fastener
installation, clamp load, tool access and electrical function are not affected.

2.3.7 Insulation crimp width I.C.W.

Measure crimp widths at initial setup and after making tooling changes and compare
to requirements of approved crimp development table.

2.3.8 Insulation crimp height I.C.H.

Measure crimp height at initial setup and after making tooling change, compare to
requirements of approved crimp development table.

2.3.9 Terminal Bend

Controls on terminal bend angle are required to assure product performance.
Terminal bend angles are supplied by the terminal manufacturer. In cases when the
terminal bend angle is not specified, the wire harness suppliers must follow the
direction as outlined.

For male crimp terminals, the bottom of terminal box should be fixed flat without
constraining the conductor crimp. Crimp tooling should be designed to avoid contact
with the male blade in order to prevent damage.

Male Terminal

For female crimp terminals, the bottom of the terminal box should be fixed flat without
constraining the conductor crimp.

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GIS2 Classification: Confidential Date Issued: 1998/01/27
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 Engineering Specification
ES-BU5T-14A121-AA

Female Terminal
If the wire harness supplier does not have the ability to measure as indicated by the
terminal manufacturer or as above, a checking aid is required to align the box of the
terminal and check the angles as required.

2.3.10 Conductor Crimp Roll

Controls on terminal roll angle are required to assure product performance. Terminal
bend angles are supplied by the terminal manufacturer. In cases when the terminal
roll angle is not specified the wire harness suppliers must follow the direction as
outlined.

2.3.11 Fractures
No fractures are permissible. (Special attention should be provided to the transition
area of the terminal between the conductor wing and body or conductor wing and
insulation grip).

2.3.12 Bellmouth (Flare) The conductor grip (d.) must have a bellmouth
(flare) or a raised (two stage) crimp on the side of
Bellmouth (flare) is the grip nearest the insulation grip.
required here The conductor grip may also have a bellmouth
(flare) on the front edge of the conductor grip,
nearest the terminal body.

Bellmouth (flare) on the insulation grips (e.) should

not exceed the insulation crimp tolerances.

d
.

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GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331
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ES-BU5T-14A121-AA

2.3.13 Cut-off Tab

The cut-off length shall not exceed 0.5 mm, unless otherwise specified on the
component print, or protrude from the connector cavity. The burr on the cut-off must
not exceed 0.3 mm, unless otherwise specified on the component print. The cut-off
and burr must not affect the insertion function of the terminal into the connector.

2.3.14 Missing or Broken strands

No broken or missing strands are allowed on 7-strand or fewer strand construction.
One broken or missing strand is allowed on 19-strand cable. All terminations,
containing missing or broken strands, must be validated per paragraph 2.1 of this
specification. Supplier Product Engineering must approve missing strand count cable.

2.3.15 Individual Wire Seal and Mat Seals (Terminal pushed through seal)
The individual wire seal must be firmly secured by the insulation crimp. The
individual wire seal must show no signs of damage. The individual wire seal shall
be visible between the insulation and conductor crimp wings.
The cable insulation must be visible beyond the end of the individual cable seal.

Terminals that are pushed through Mat Seals must not cut or damage seals such
that USCAR Submergible Sealing Test will not meet acceptance criteria. One of
the ways this may be assured is to have crimp tooling such that the front of crimp
wire strands are pushed or held down during the crimping process and controlled
wire handling to prevent high strands that will cut seals. Periodic microscopic
inspection and visual inspection standards should be done to make sure the
process is in control.

Requirements EL-0038 and EL-0176 call out retention force requirements for
individual wire seals. These forces must be met but direct measurement as an
in-process control is not required; meeting insulation crimp dimensions is
sufficient evidence that the seal retention in-process matches the retention forces
measured in the lab.

These factors must be managed to avoid damaging mat seals: Wire brush, anvil
flash, conductor crimp bend angle, insulation crimp bend angle, CCH/CCW, grip
offset, cut off.

2.3.16 Pull Testing

Since CCH is the primary control for proving crimping process capability pull
testing should not be used for this purpose. If pull force testing is done, it shall be
performed per applicable sections of USCAR-21.

2.3.17 Cut or pierced insulation

The crimping and/or wire cutting process must not damage the cable insulation.
Periodic inspection should be done to make sure the process is in control.

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GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331
 Engineering Specification
ES-BU5T-14A121-AA

2.3.18 Termination Sensors

Equipment that will monitor the crimping process during termination of the circuits
(termination sensors) is preferred.

2.4 Eyelet Crimp Sealing or Insulating

Per design rule 1801_ED-22, any eyelet that has a shrouded, covered, or insulated
crimp must have that shroud/cover/insulation cover the entire crimp and extend a
minimum of 3 mm beyond the terminal/crimp interface onto the wire insulation (NOTE
TO DESIGN ENGINEERS: this applies to powered-at-all-times eyelets).

Methods used to seal or insulate eyelet crimps must not interfere with terminal fit and
function – e.g., the heat-shrink adhesive must not flow onto the interface (flat)
surfaces of the eyelet, the tubing must not extend onto the interface surfaces, etc.
Eyelet crimps that are sealed must meet the requirements of ES-F0EB-1A263-AA,
section 2.

3.0 Soldering Requirements

3.1 Every wire harness supplier must have an approved control plan for all types of
soldering processes. Only lead-free solders may be used. This is required for
compliance with the Ford Restricted Substance Management Standard (RSMS -
WSS-M99P9999-A1).

3.2 Dip soldering the terminal and conductor crimp is normally used on ring (eyelet)
terminals, bulb contact terminals, or where specified on wire assembly drawings.
Crimps validated per EL-0038 or EL-0176 do not require soldering unless specified on
the wire harness print for additional corrosion or water protection.

3.3 Re-flow (point) soldering of the conductor crimp is typically used where dip soldering
would interfere with terminal fit or function (such as a female terminal with a spring
member).

3.4 When certifying crimp dimensions, the conductor crimp height dimension on a solder-
dipped terminal should have its + tolerance increased 0.10 mm to allow for the
thickness of the added solder. (FOR FINISHED HARNESS AUDITS ONLY)

3.5 Dip Soldering

Dip soldering is defined as the process of dipping the terminal into molten solder so
that the solder flows into the crimp. Forms a bond between the conductor and the
terminal and subsequently evenly coats the entire terminal with a layer of solder.
This soldering method must assure that excess solder does not adhere to the
terminal such that it interferes with function or fit. Parts to be soldered must be clean.

Global Manufacturing Quality FRAME 9 OF 33

GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331
 Engineering Specification
ES-BU5T-14A121-AA

3.6 Re-flow Soldering

Re-flow soldering shall be defined as the process of heating a conductor crimp,
where a pre-stripped and solder- dipped conductor has been crimped to a pre-tinned
terminal, so that the solder melts and re-flows into the conductor crimp to form a
solder bond between the conductor and the terminal.

3.7 Spot Soldering

Spot soldering shall be defined as the process of heating a conductor crimp and
applying solder. The solder must not flow into the insulation or interfere with terminal
function.

4.0 Splicing

Splices shall be made using methods (e.g. resistance welding, ultrasonic welding, crimping
and soldering, etc.) appropriate to the application where process capability has been
demonstrated and documented.

Splice clips are allowed as long as EL-0038 (RQT-180107-008676) section 7 requirements

are met, including the requirement that the current rating for the clip be equal to or greater
than the current being handled by the splice.

Spot soldering, per section 3.7, is not allowed as a method for using splice clips that do not
pass the electrical resistance specification of EL-0038.

4.1 Requirements
Any method that is used to hold the strands of wire together into a splice must
capture all strands of the affected wires. These splices must be free of any broken
strands or strand ends outside of the bond that could pierce or extend outside molds,
tape, heat shrink tubing or other splice covering.

Center strip splices must meet the same requirements as end strip splices. By
definition, center stripped splices have the insulation removed from a length of the
cable rather than the end, such that another center stripped wire or end stripped wire
can be spliced to it.

Splices that are to be sealed are to be constructed such that the distance between
the nugget and the wire insulation is 3.5 +/- 1.5 mm and that the amount of overlap
between the farthest conductive surface and the sealing material is at least 3 mm.

4.2 Splice Pull Test

Cables spliced by splice clips shall not pull out of the splice clip when the smallest
size cable in the splice is subjected to a force equal to the pull out force per
specification USCAR-21.

Global Manufacturing Quality FRAME 10 OF 33

GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331
 Engineering Specification
ES-BU5T-14A121-AA

Cables spliced by welding or soldering shall not pull loose from the splice nugget
when the smallest size cable in the splice is subjected to a force equal to the pull
force per the following table. The pull forces for unlisted wire sizes can be defined by
linear interpolation (i.e. read out from plotted values in the following table). It is
preferred that welded splices be 100% monitored by a weld quality monitoring
system for improved weld quality.

Wire Gage (mm²) Wire Gage (AWG) Minimum Pull Force (N)
0.13 26 21
0.22 24 35
0.35 22 55
0.50 20 75
0.75 108
0.80 18 110
1.0 16 155
1.5 216
2.0 14 290
2.5 317
3.0 12 360
4.0 397
5.0 10 450
6.0 597
8.0 8 890
10.0 1283
16.0 2163
The pull test shall be applied to a minimum of three samples per hour or three per
3000 pieces, whichever comes first, using one cable on each side of the splice
simultaneously.

Sample size and/or frequency are permitted to be at a reduced level if the supplier
has a control plan and can demonstrate process capability. Sample cables of the
same construction type are permitted for splice pull testing in lieu of production
circuits.

4.3 Splice Peel Test

Test equipment: tensile testing machine

Test conditions: tension speed: 100 mm/min

tension direction: radial to the joint
wire with the smallest cross section (a) should be tested.
wire with the biggest cross section (b) should be used on the
other side for fixing/retention.
test temperature: room temperature

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 Engineering Specification
ES-BU5T-14A121-AA

Minimal peel strength depends on the wire cross-sectional area. Note that 0.13 mm2 wire does
not have a peel force value, as any splice using that wire must also have dual-wall heat shrink
tubing applied.

Wire 0.35 0.5 0.75 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.0 10.0 16.0
CSA
(mm2)
Peel 10 14 23 28 35 41 44 53 62 73 88 124 159
Force
(N)

4.4 Insulation
When wires are joined in a wiring assembly by splicing, the splice shall be insulated
as specified on the drawing.

4.4.1 Dry Areas Only

Option A: WSS-M99D69-A2 single wall heat shrink non-adhesive tubing. The
formerly approved ESF-M3L66-A has been replaced by WSS-M99D69-A2 and
is no longer active.

Option B: Tape meeting ES-AC3T-1A303-AA (minimum 38 mm wide) applied

so that all exposed surfaces of the splice are covered by a minimum of three
thicknesses of tape.

Option C: Heat shrink tubing meeting the following specifications: ES-3M5T-

1A263-AA (rated to 125 °C); ES-2S7T-1A263-AA (rated to 150 °C); or ES-
3M5T-1A263-CA (rated to 200 °C)
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 Engineering Specification
ES-BU5T-14A121-AA

4.4.2 Wet or Dry Areas

Sealed splices must meet the requirements of ES-F0EB-1A263-AA using
either Option D, Option E, or Option F.

Option D: Heat shrink adhesive (Dual Wall) ESB-M99D56-A2 or

WSS-M99D56-A4.

Option E: Liquid sealant as specified in Appendix A (specify on harness prints

by manufacturer’s name and product number)

Option F: Heat shrink tubing meeting the following specifications: ES-3M5T-

1A263-BA (rated to 125 °C) or ES-2S7T-1A263-BA (rated to 150 °C)

Products other than these may be used if reviewed and approved by Ford
EDS Core.

4.5 Location
Splice locations, as noted on detail drawings, may not be relocated without prior
Product Engineering authorization. Use tolerance of +/- 13 mm unless larger
tolerance is permitted on chart per 7.2 of this document. If tolerances larger than +/-
13 mm are being used, then Product Engineering authorization is required in order to
insure that the splice location does not impact the design.

5.0 Outer Covering

The outer covering for wiring assemblies shall conform to the specifications (material or
performance) referred to on the face of the drawing. All unbound wires must be held under
covering at takeout points where required for manufacturing feasibility. The use of spot
taping, diaper wrapping, tape wrapping, etc., is acceptable for this application. Wire loops
protruding from any gaps in the covering are not acceptable.

5.1 Tape
Full tape wrap must be applied neatly and be free of open sections. The wings of the
retainers are to be covered completely with the tape. Spaces between wraps are
permissible only at fold points that may occur during handling and packaging. Spaces
between wraps which are apparent only in an intermediate stage of assembly (i.e., a
takeout on a PIA part is stowed for shipment), or which are invisible when the
harness and all takeouts are installed in proper vehicle position, are permissible.
Unsecured ends of non-adhesive coverings must be secured with an adhesive tape
or other approved method.

Candy striping (spiral wrapping) is permissible as a manufacturing aid when

approved by the design activity and will have no effect on the function of the wiring
design. On machine wrapped assemblies where percent of wrap overlay is
dependent on harness diameter, spaces between wraps are permissible at points of
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GIS2 Classification: Confidential Date Issued: 1998/01/27
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 Engineering Specification
ES-BU5T-14A121-AA

an abrupt diameter increase or at points where differentials in circuit lengths must be

absorbed. Loops of wire protruding through the spaces between the wraps are not
acceptable. The minimum number of wraps for any harness section length shall be
according to the following table:

Tape Width Harness Wraps per

Diameter 300mm (Min.)
19mm 3 - 8 mm 8
19mm 8 – 13 mm 14
19mm 13-19 mm 15
19mm 19 mm and up 16
25mm 8 – 10 mm 9
25mm 10 – 15 mm 10
25mm 15 – 25 mm 11
25mm 25 mm and up 12

Candy striping (spiral wrapping) is permissible when specified on the assembly print.
The assembly print shall take precedence over the values in the table above.

5.2 Taping to the back of connectors

Tape wrap shall stop at a distance back from the connector equal to the maximum spread
between terminal cavities on that connector plus 5 mm, with a +/- 5 mm tolerance (distance
D1). This distance is to be considered as fully taped all the way to the back of the
connector (See figure 1 for non-dressed connectors and figure 2 for dressed connectors). If
the connector is not fully populated – that is, if the wires in a connector are arranged in such
a way that the maximum spread between wires is less than the maximum spread between
terminal cavities, then tape wrap may be applied closer than the maximum spread between
cavities, stopping at the maximum spread between wires. If the connector is populated
differently in different versions/levels of the same harness, then for ease in manufacturing,
the taping for all versions/levels may stop at distance D1 as defined above; it will be
considered as fully taped all of the way back to the connector for all versions/levels of that
harness takeout.

Braid (non-metallic braided or knitted hoses)

Due to the disturbances that unbalance the equal tensions required on all braided
threads, a harness section containing an abrupt diameter change or takeout point may
have loose braid. This area should not exceed 125mm of linear length before balance is
re-established. In other sections of harness, where the diameter is consistent and there
are no takeouts, the braid shall be applied in a neat, uniform manner. The braid shall be
securely taped to the wire at both ends, and the pigtail shall not exceed 40mm-in length.

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5.3 Avoiding wire damage from coverings

Harnesses must be constructed so that any harness outer covering (tape, tubing, shields,
etc.) must not be able to damage the wires during and after installation in the vehicle (ref.
SDS requirement RQT-180100-009524). Here are some examples:

• Wires must not splay out of the slits in convoluted tubing

• Wires must not be able to contact or chafe on the edges (cut ends, slits, etc.) of
convoluted tubing

• Harness takeouts may not exit convolute through the slit; the tubing must be broken
or divided at the takeout point

5.4 Applying Other Coverings to the Back of Connectors

Other coverings shall stop at a distance back from the connector equal to the maximum spread
between terminal cavities on that connector plus 5 mm, with a +/- 5 mm tolerance (distance D1).
This distance is to be considered as fully covered all the way to the back of the connector (See
figure 1 for non-dressed connectors and figure 2 for dressed connectors). If the diameter of the
other covering equals or exceeds the maximum spread as defined above, then it may go all the
way to the back of the connector. If the connector is not fully populated – that is, if the wires in a
connector are arranged in such a way that the maximum spread between wires is less than the
maximum spread between terminal cavities, then the other covering may be applied closer than
the maximum spread between cavities, stopping at the maximum spread between wires, or all the
way to the back if the diameter is larger than the maximum spread between wires. If the connector
is populated differently in different versions/levels of the same harness, then for ease in
manufacturing, the covering for all versions/levels may stop at distance D1 as defined above; it will
be considered as fully covered all of the way back to the connector for all versions/levels of that
harness takeout. NOTE: this section does not apply to coverings that are intended to cover the
connector completely, e.g. for heat shielding.

6.0 Molding/Insulation

Where mold/insulation is called out, the following criteria are required (Ref.: ES-C0AF-
14A121-A, Part ll).

6.1 Durometer
All D-mold connectors (Ref. Spec. ESB-M4D317-A) with female terminals and all
skirted connectors must use Type III compound (unless otherwise specified). All
other D-mold connectors shall use Type IV or V (unless otherwise specified.)

6.2 Coloring
Molding compound shall be black (unless otherwise specified on the face of the
assembly drawing or the individual item detail).

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6.3 Removed

6.4 Grommet Pull Test

Grommets on any assembly drawing must withstand the pull force as identified below
unless otherwise specified (pull force to be applied longitudinally along harness).

Pull Force

Application
(Newtons)
Over tape, single or multiple wires. 110
Use of retaining clip, strap, etc. is optional.
Over vinyl tubing or vinyl jacketed cable. 110
Over braid. 65
Over non-metallic conduit 65

7.0 Dimensioning and Tolerancing

Section: Dimensioning. All takeout dimensions are measured to the centerline of the
harness bundle unless otherwise specified. All harness dimensions for connectors are
measured to the back face of the connector or to the defined attachment point in the
connector model as shown on the harness print unless otherwise specified. All harness
dimensions for eyelet terminals are measured to the center of the eyelet hole unless
otherwise specified. See Figure 3 for details. All retainer/clip dimensions are measured to
the centerline of the attaching feature (e.g., retainer fins, stud channel, portable hole, etc)
unless otherwise specified on the drawing.

Section: Angular Tolerances. Angular tolerances, shown on views or sections, shall be +/-
45 degrees unless otherwise specified.

7.1 Single Wire

Bundle length Tolerances for Single Wire Assemblies (unless otherwise specified):

Over Including Tolerances

15mm 75mm +/- 8mm

75mm 380mm +/- 10mm

380mm 3050mm +/- 20mm
3050mm Up +/- 40mm

7.2 Multiple Wire

Bundle length Tolerances for Multiple Wire Assemblies (unless otherwise specified):

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Cumulative
Over Including Tolerances Limits*
(mm) (mm) (mm) (mm)

10 50 +/- 6 +/- 10

50 150 +/- 10 +/- 15

150 300 +/- 20 +/- 25

300 900 +/- 25 +/- 40

900 2500 +/- 30 +/- 50

2500 Up +/- 50 +/- 60

*The total length of any two or more adjacent bundle lengths along the “main”
harness or along a takeout back to the “main” harness must be equal to the sum of
their nominal dimensions within the cumulative limits specified above, while not
exceeding the tolerance of the individual bundle lengths. Only nodes used to identify
bundle segments, connector end points, or datums are to be included in the
cumulative limit calculations. See Figure 4 for a cumulative tolerance example.

Assembly drawings documenting tighter tolerances, or at different points than what

are shown in Figure 4, take precedence over this specification.

7.3 Tape Ties

Tolerance for locating dimensions of tape ties and locator bands on wiring
assemblies shall be +/- 15 mm unless otherwise specified. If tape ties are used for
locating retainers or other retention features, then the tolerance in section 7.4 is to be
used.

7.4 Retainers and All Other Components

Tolerance for locating dimensions of retainers and all other components (ID labels,
shields, etc.) shall be +/- 10 mm unless otherwise specified on the assembly drawing.
For example, this applies to any dimension involving a retainer/clip (clip-to-clip, clip to
connector, clip to takeout, etc.).

Unless otherwise specified on the harness print, tolerances are based on the
adjacent bundle segment length to the next fixed point node (e.g., retainer/clip,
takeout point, connector, etc.). Tape ties, end of coverings, and reference
dimensions are not to be considered as fixed points. See Figures 5 and 6 for
examples. Nodes, used to identify the position of other components (e.g., grommets,
shields, brackets, etc), are tied to a fixed point on the component (e.g., grommet
end/tape tab, shield tape tab, centerline of grommet sealing interface, etc) Views and
sections are typically used for clarification.

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7.5 Retainer Pull Force Requirement

Single plastic locator clips, or clips sub-assembled to plastic strips, are to be fastened
in place on the wiring assembly so that a minimum of 110 Newtons (or other value
specified on the component or harness print) is required to pull the clips off the wiring
assembly. The pull force is to be applied perpendicular to the wiring assembly
longitudinal axis in the direction of the locator.

7.6 Wire Harness Neatness

Looped wires are not allowed inside of any harness bundle unless specified on the
harness print or specifically authorized by Ford Engineering.

Circuits entering connectors must have their lengths adjusted to prevent stress from
being applied to any circuit or causing connector seals, especially mat seals, to be
deformed.

Tape, including packaging/hanking/tear tape, applied to electrical connectors must

not interfere with their locking or mating features.

Tie-strap retainers must have their excess strap material cut flush to the lock, with a
maximum of 3 mm excess material permitted.

8.0 Materials
8.1 Wire Materials
8.1.1 0.13 mm2 Wire Materials

The only allowable wire conductor materials to be used in CAN circuits are:
a. CuSn (Copper-Tin)
b. CuMg (Copper-Magnesium)
c. Cu-Co-P (Copper-Cobalt-Phosphorus)

For the latest approvals, please contact the EDS Core wire specialist.

8.2 Compatibility with Wire Insulation

Any substance (e.g., grease, lubricant, cleaner, etc.) that can come into contact with
the wire insulation, whether it is deliberately applied or has incidental contact, must
not cause the insulation diameter to change by more than 10%, to crack, or to
otherwise degrade. This is to be verified by performing the Fluid Compatibility test of
SAE J1128, section 6.7 on the substance/insulation combination(s) in question.
Combinations previously tested do not need to be retested.

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9.0 Shielding Composition

9.1 General
Drain wire designated as circuit DXXaa (example: DE135) in ES-6L2T-1274-AA,
when used in shielding application, will be tinned, uninsulated, copper wire - twisted
stranding, spirally wrapped over specified circuits at a spacing of one wrap per 75-
100mm.

For a single twisted pair application using a drain wire, a permissible alternate
construction is to lay, instead of twist, the drain wire along the specified twisted
circuits then wrap with foil tape as specified below.

For multiple twisted pairs under a common shield, a permissible alternate

construction is to use a single drain wire twisted at a spacing of one wrap per 75-
100mm around all pairs then wrap with foil tape as specified below.

All circuits will then be spirally wrapped and lapped (50% overlap), with aluminum foil
tape, over the twisted tinned stranding. Only the tinned stranding is to be terminated -
the aluminum foil tape is to be secured at each end with adhesive tape to prevent
unraveling. The adhesive tape must be appropriately rated for the environment in
which it will be used. The aluminum foil tape is to have the following construction and
characteristics:

Laminate dimensions:

Aluminum foil 0.008 mm

Polypropylene film 0.025 mm

Aluminum foil 0.008 mm

Breaking strength: 10.875 KG per 25 mm width

Tensile strength: 86,034 KPa

Elongation at Break: 35%

Gauge: 0.042 mm

Width: (To Be Determined by Wire Harness Supplier – typically 20-25 mm)

Color: Natural (silver/reflective)

This tape is to be identified on harness prints with the suffix ‘(FT)’ – thus, ES-BU5T-
14A121-AA (FT).

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ALTERNATE CONSTRUCTION: use foil tape meeting performance specification ES-

BU5T-1A303-AA. Alternate constructions employing single sided foil per ES-BU5T-
1A303-AA must be reviewed and approved by the Ford subsystem owner and Ford
EMC groups.

Where specified, shielded wire groups must be insulated from each other or
unwanted grounds. If two or more foil-wrapped circuit groupings share a harness
bundle, then each grouping, except for one, is to be spirally wrapped and lapped
(50% overlap) with a non-conductive tape meeting ES-AC3T-1A303-AA or its
successor spec.

9.2 Shielded Drain Wire

The non-terminated end of the drain wire must be protected such that the ends
cannot penetrate adjacent wires to cause a shorting condition. Suggested shielding
methods include heat shrink, hot melt, or Tape.

10.0 Sealed Connectors

A check must be conducted to ensure unused cavities are plugged (e.g.: leak (vacuum or
pressure) testing, presence check, etc). The wire insulation should not be damaged or
deformed beneath the sealing area; processing equipment should not handle the wire in this
location.

10.1 Mat Seals

No seal material shall be dislodged (i.e. torn away) during the plugging or servicing
(i.e. removal and re-plugging) of the terminal through the seal. Crimp tooling shall
depress the wire strands and control the cut-off tabs as described in SAE/USCAR-21
to prevent such damage.

Fluoroplastic or fluoropolymer insulation is not to be used in mat seal connectors

without successfully passing the SAE/USCAR-2 5.9.7 Sealed Connector System
Environmental Test Sequence. Manufacturing plants will either need to obtain this
test data or perform the tests themselves.

10.2 Individual Wire Seals

The seal must be firmly secured by the insulation crimp. The seal must show no
signs of damage. The end of the seal neck must be visible in the area between the
insulation crimp and the conductor crimp. The cable insulation must be visible under
the seal.

Note: Seal retention is assured by meeting in-process insulation crimp dimensions

per EL-0038 part 3. No additional in-process testing is required.

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10.3 Cavity plugs

Per SDS requirement EL-0178 (RQT-180107-008730), a tool must be used to install
cavity plugs such that the plugs are installed in position 2, as shown in Figure 7. The
plugs must be installed prior to any terminals being plugged. If a tool proves
impractical, alternate methods for installation may be used if approved by EDS Core
or Core Connectors.

11.0 Terminal Secondary Locks (a.k.a. TPA)

As a manufacturing/assembly reliability feature, many connector assemblies utilize a

secondary terminal lock/inspection component, such as a wedge or spacer (typically front
loaded at the mating end). All wire assemblies shall have the presence and correct position
of this terminal secondary lock inspected. Any tool or mechanical assist device used to
install the terminal secondary lock must be approved by Ford Connector Engineering.

In those instances where there is no terminal secondary lock, then inspection equipment
must verify that all terminal plastic lock fingers in the connector are seated. If these
deflected plastic terminal lock fingers cannot be detected, then terminal push-out testing per
Section 11.1 is required. All of these inspections must be performed prior to final electrical
continuity testing.

11.1 Terminal Push-out Testing

Push test must be done using a push test fixture constructed such that properly
seated circuits remain in design position during a 13 to 22 Newton applied force and
improperly seated terminals "pushout" and are detected. If any circuits fail the push
test, all circuitry in that connector must be electrically re-tested after repairs are
made.

12.0 Electrical Requirements

After the harness is completed through the total manufacturing process, all wiring
assemblies must be electrically tested. The electrical test must check for crossed circuits,
continuity, opens, and shorts; the electrical test shall be conducted sequentially, testing
each circuit and each branch of each circuit (including diodes and relays). Relays are to be
functioned once to verify basic operation; apply a voltage of range 9 to 13 V to the coil to
energize it and verify continuity through the contacts. Harness makers will electrically test
shorting bar circuits for continuity when unmated and for lack of continuity when the shorting
bar is deflected to simulate being mated to the appropriate connector. The presence and
continuity of busing circuits or components (bus bars), excluding fuses, used to short
harness circuits must be tested. Re-testing of all positions will be required for any connector
which fails to have every position successfully tested. Additionally, the presence of the
correct components is to be checked (locators, molds, clips, connectors, TPA's, seal plugs,
fuses, circuit breakers, etc.).

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The wiring assembly supplier is responsible for the design of fixtures which contact or probe
terminals, for the purpose of electrical inspection. These fixtures must be designed such that
they are harmless and compatible with the component.

At the completion of a successful test, the test system must provide the operator with a
"success signal" (or release a locking mechanism on a wire assembly as a result of the
successful test) which is significantly different from the various in-process test signal(s)
emitted during other states of harness testing. For example, if numbers are displayed
during other stages of testing, the "success signal" may not be a number.

12.1 Fixtures Which Contact Terminals

Any design fixture may become damaged or degrade over time causing the forces
they apply to the harness terminals to increase above fixture design intent.
Regardless of component capability, fixtures which contact or probe terminals (e.g.,
continuity fixtures) shall meet SDS requirement EL-0052 (RQT-180107-008690.
When female barrel terminals of different inside diameters, but having construction
similar enough to allow them to fit into the same terminal cavity of a connector, are
used on the same circuit, any check must assure that the correct terminal has been
used. This applies to single circuits and to circuits that are joined by means of a
splice. When the condition occurs within a splice, if the lengths of the circuits could
not physically be mixed, the difference in length can serve as the means to assure
that they will not be used incorrectly.

12.2 Electrical Control/Maintenance Plans

Wire harness suppliers must have control plans or preventive maintenance plans for
their fixtures which contact or probe terminals. These plans must define the
frequency of fixture inspections to verify compliance to paragraph 12.1 and reaction
plans to ensure customer protection when non-compliances are found.

EL-0052 is the requirement for test fixture development. In addition, some terminal
and connector drawings call out probe design and location of contact. When
available these guidelines must be followed as well.

Wire harness suppliers must have control plans and maintenance/replacement plans
for reusable harness assembly aids.

Grease applicators, when used, must not come into contact with the terminals and
must be documented in the control plan.

12.3 Diodes
When diodes are present in the circuit being tested, specific diode polarity and
function must be tested after covering, but may be in sub-assembly. Testing to verify
diode polarity and function is accomplished by retesting with the polarity reversed
from the initial test set-up.

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12.4 Similar Terminals in the Same Connector

When similar terminals, but with different part numbers, are used in the same
connector, a check must be conducted to assure that the correct terminal has been
used in each connector cavity location. This check may be visual, but the minimum
frequency of inspection must be once per shift. The frequency of inspection may be
reduced once the process has been proven capable, however. The inspection data
and process capability must be maintained by the wiring supplier and made available
to any customer representative upon request.

13.0 Identification

Multiple wire assemblies shall be identified with a label per either ES-2U5A-1289-AA, ES-
HU5T-1289-AA or as shown below unless otherwise noted. The label shall be located per
drawing note. The program’s Engineering Sgtatement of Work (ESOW) will specify which
label spec to use.

13.1 Label Characteristics

The label material is to be water-resistant and UV-light-resistant.

Print Carrier

• Material
Extruded film, white, gloss, non-PVC

• Tear strength longitudinal (DIN 53455) 18 +/- 4 N/mm2

Adhesive

Must conform to the following: “Any change in materials or source of used parts will
result in testing to determine materials’ compatibility with associated wiring
components. Compatibility testing is to be conducted at the appropriate temperature
range for that application.”

13.2 Printing Method

Reference: Thermal transfer printing is one of the most widely used technologies in
the industrial world to print labels and tags on site and on demand. The printed image
is produced using an inked thermal transfer ribbon. Heat is applied by the printhead
which melts the ink and transfers the image onto the printing medium.

TTP printing using the „ in line“ technique enables direct printing on materials like
labels or tags. The printed image obtained using thermal ribbons will be resistant to

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UV-light, have good edge definition and bar codes will be scannable provided the
correct head and speed settings have been used.
Ford bar code has to contain the part number in alphanumeric form, code number to
be used is 128B. A translation of the bar code, as commercially used underneath in
small fonts, is allowed but not required.

Note: Alternative printing methods like laser etc. having comparable printing
performance and durability are accepted as well.

Position 1 – 5 Prefix
Position 6 – 11 Family No. (Base-No.)
Position 12 – 14 Suffix

13.3 Design and Proportions

max.66 mm

3 mm

5 mm
X S 7 1 -1 4 4 0 1 Part No. (Bold)

AAA
3 mm

11 mm Suffix (Bold)

3 mm
2 mm EE00-E-10473585-000 Release No.
3 mm
2 mm A10744765 Potential Alert 2 Potential Alert No.
3 mm
2 mm Potential Alert 3 Potential Alert 4 Potential Alert No.
3 mm

max. 100 mm
7 mm

3 mm
Ford Min. 7 Depentent On No. Of
Alert (Bold&Italic)
Central Line (bold)
3 mm 15 mm
Country & Supplier Code (thin lines)
3 mm S-SK For Plant Disposal
3 mm
Dash lines (thin)
Free Field For Supplier Internal
11 mm For Supplier Disposal
Information (Barcode etc.)
Dash lines (thin)

AAA
3 mm

11 mm Suffix (Bold)

3 mm

10 mm Barcode Ford (Typ 128B)

3 mm

All fonts shall be Arial or similar and font size as close as possible to the one shown
in the specification.

13.4 Single Wire and Rip Cord

Single wire and ripcord assemblies may be marked by printing directly on the
conductor insulation. Double (2) wire assemblies, which are not covered (with tape or
other jacket), may be marked by printing directly on the conductor insulation of one or
both wires. This printing is an acceptable alternative to the applied printed tape or
tag, even when a tag is specified on the part drawing. Printing shall be black, except
on dark range base wire colors where printing shall be white.

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14.0 Shipping Requirements

Connectors on harnesses are to be shipped in a ready-to-be-installed configuration. Other

than the removal of protective coverings, shipping caps or harness hanking tape, the
connectors must be ready to be mated or installed with no additional actions required by the
operator. Exceptions require approval of EDS Core and EDS Core Connectors. All
approved exceptions shall be shown on the connector drawing.

To prevent warpage and cracking, ensure that packaging/dunnage eliminates high forces on
connectors and other plastic components. Force limits should be obtained from the
component owners through discussions between the harness suppliers and component
suppliers (example: tier 2 SCCAF).

Terminals within connectors are to be protected from damage during packaging and
shipping. Contact to terminals by any part of the harness or other harnesses within the
dunnage must be prevented.

15.0 Black Box Components

Components shown on supplier drawings with Ford part numbers shall be processed in
compliance with all written specifications and instructions provided by the component
supplier. This does not apply to terminal suppliers' crimps applications, which must be
reviewed for compliance to SAE/USCAR-21. (Specification must contain an electrical
verification test of crimp performance).

Attachments
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X+5

Figure 1

Min. bend Radius: 2.5 * Bundle Diameter for copper conductors and 5.0 * Bundle Diameter for
aluminum conductors
Note 1: Circuits/Wires exiting the covering are to maintain a minimum bend radius of 2.5 * Bundle
Diameter for copper conductors and 5.0 * Bundle Diameter for aluminum conductors and have
sufficient and equal slack to prevent stress on the individual wires.
Note 2: X is the maximum spread of terminals in the connector

Figure 2

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Figure 3

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Figure 4

Figure 5

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Figure 6

Figure 7
TABLE 1: TESTS THAT QUALIFY AS PV AND IP

Tests/Procedures Section No. PV IP Sample Comments

of Mfg. Size
Spec
Splice Pull Test 4.2 X X Reserved
Splice Peel 4.3 X X Reserved Splices
USCAR-38 Section 4.3 X X Reserved Ultrasonically Welded Eyelets
4.4 Peel Force
ES-F0EB-1A263-AA 2.4, 4.4.2 X X Reserved Bubble test
Section 2

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Grommet Pull Test 6.4 X Reserved

Connector Seal 10.1, 10.2 X X Reserved
Checks
100% Electrical 12.0 X X Reserved
Check
Diode Check 12.3 X X Reserved
Proper Terminal 12.4 X X Reserved
Checks
Terminal Pull-Out 2.3.16, X Reserved
Force Test USCAR 21
Torque Test X Reserved
USCAR-21 Tests X Reserved
USCAR-38 for All X X Reserved Visual Inspections – primarily IP,some PV
Ultrasonically Section 4.4, peel and pull force - PV
Welded Eyelets Section 4.7, Electrical Performance
Test (PV)
Tests in Appendix C, Weld
Development and Geometry (PV)
Clip pull-off force 7.4 X Reserved
from bundle
Note: Ford EDS and Ford STA to review and approve all proposed PV and IP Testing.

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APPENDIX A
This appendix contains the content of Ford Material Specification WSB-M4G352-A, which had been specified as the
liquid sealant to use per section 4.4.2, option F, of this specification.. M4G352 is currently (March 2017) in N status,
meaning it is not to be used for new programs, and is likely to be inactivated. The intent is that the performance
requirements for the sealant be met; other sections are to be regarded as reference material.

1. SCOPE

The material defined by this specification is a thermpolastic blend of

polymers and synthetic elastomers.

2. APPLICATION

This specification was released originally for material used to seal wire
splices in electrical wiring harnesses. It is applied by a process of
dipping a splice in the heated molten material. After cooling, this
material provides an effective flexible encapsulation.

3. REQUIREMENTS

In addition to the requirements specified herein, the finished encapsulated

splice shall pass applicable performance specifications specified on the
engineering drawing.

3.1 STATISTICAL PROCESS

Suppliers must conform to the requirements of Ford Quality System

Standard Q-101. A mutually acceptable Control Plan as described
therein is required for material/source approval. Appropriate
statistical tools must be used to analyze process/product data so
that variation in the final product is continuously reduced.

3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS

Ford Motor Company, at its option, may conduct infrared and/or
thermal analysis of material/parts supplied to this specification.
The IR spectra and thermograms established for initial approval shall
constitute the reference standard and shall be kept on file at the
designated material laboratory. All samples shall produce IR spectra
and thermograms that correspond to the reference standard when tested
under the same conditions.

3.3 CONDITIONING AND TEST CONDITIONS

All test values indicated herein are based on material conditioned in

a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative
humidity for not less than 24 h prior to testing and tested under the
same conditions unless otherwise specified.

3.4 DENSITY AT 23 C 0.76 - 0.96 kg/L

(ASTM D 1475)

3.5 VISCOSITY 560 - 2790 mPa.s

(ASTM D 4402, Brookfield Thermosel Model
RVT, #27 spindle, 20 rpm, 177 C)
Global Manufacturing Quality FRAME 31 OF 33
GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331
 Engineering Specification
ES-BU5T-14A121-AA

3.6 LOW TEMPERATURE FLEXIBILITY at - 30 C No cracking

Test Method: Condition a 25 x 200 x 0.5 mm strip of material for 24
h at - 30 C. Then flex it five times around a conditioned 12 mm
mandrel.

3.7 WATER ABSORPTION, max

(ISO 62, Method 1)
24 h immersion 0.0 %
4 weeks immersion 0.0 %

3.8 COPPER CORROSION No discoloration

(FLTM BU 106-01)

3.9 DIELECTRIC BREAKDOWN STRENGTH 10 kV/mm

(IEC 243/ASTM D 149, short time)

3.10 OZONE RESISTANCE Rating 0

(FLTM BP 101-01)
No checking or crazing visible under 7X magnification.

3.11 FLAMMABILITY
(ISO 3795/SAE J369)
Burn Rate, max 100 mm/minute

3.12 FOGGING
(FLTM BO 116-03)
Fog Number, min 75
The formation of droplets or coalescence into a clear film is cause
for rejection.

3.13 HEAT AGED

(ISO 188/ASTM D 573, 150 +/- 50 air
changes/h, 1000 h at 80 +/- 2 C)
3.16.1 Hardness Change, max +/- 20 %
3.16.2 Tensile Strength Change, max +/- 25 %
3.16.3 Elongation Change, max +/- 25 %
3.16.4 Visual Evaluation
No surface tackiness or cracks when folded flat against itself.

3.14 STORAGE STABILITY

It is recommended that the material shall be stored at temperatures

below 70 C away from all sources of heat and sunlight. When the
material is stored at room temperatures below 23 C, it shall be
conditioned at room temperature 24 h prior to application.

3.15 FUNCTIONAL APPROVAL

Materials being evaluated for approval to this specification shall be

subjected to a production trial. Functional trial results must be
approved by the affected assembly operation and Design Engineering.
Results shall be made available to Materials Engineering prior to
material approval and release.

Global Manufacturing Quality FRAME 32 OF 33

GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331
 Engineering Specification
ES-BU5T-14A121-AA
3.16 SUPPLIER'S RESPONSIBILITY

All materials supplied to this specification must be equivalent in

all characteristics to the material upon which approval was
originally granted.

Prior to making any change in the properties, composition,

construction, color, processing or labeling of the material
originally approved under this specification, whether or not such
changes affect the material's ability to meet the specification
requirements, the Supplier shall notify Purchasing, Toxicology and
the affected Materials Engineering activity of the proposed changes
and obtain the written approval of the Materials Engineering
activity. Test data, test samples and a new code identification are
to be submitted with the request.

Substance restrictions imposed by law, regulations or Ford, apply to

the materials addressed by this document. The restrictions are
defined in Engineering Material Specification WSS-M99P9999-A1.

4. APPROVAL OF MATERIALS

Materials defined by this specification must have prior approval by the

responsible Materials Engineering activity. Suppliers desiring approval
of their materials shall first obtain an expression of interest from the
affected Purchasing, Design and Materials Engineering activity. Upon
request, the Supplier shall submit to the affected Materials Engineering
activity a completed copy of their laboratory test reports, signed by a
qualified and authorized representative of the test facility, demonstrating
full compliance with all the requirements of this specification (test
results, not nominal values), the material designation and code number, and
test specimens for Ford evaluation. Ford's engineering approval of a
material will be based on its performance to this specification and on an
assessment of suitability for intended processes and/or applications. Upon
approval, the material will be added to the Engineering Material Approved
Source List.

Global Manufacturing Quality FRAME 33 OF 33

GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) Version Date: 20150331