{"id":35310,"date":"2026-05-10T14:00:04","date_gmt":"2026-05-10T06:00:04","guid":{"rendered":"https:\/\/aviaelectronics.com\/en\/?p=35310"},"modified":"2026-05-25T13:59:39","modified_gmt":"2026-05-25T05:59:39","slug":"how-to-populate-a-d38999-shell","status":"publish","type":"post","link":"https:\/\/aviaelectronics.com\/en\/how-to-populate-a-d38999-shell\/","title":{"rendered":"How to Populate a D38999 Shell: Best Practices and Key Details"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"35310\" class=\"elementor elementor-35310\" data-elementor-post-type=\"post\">\n\t\t\t\t<div class=\"wd-negative-gap elementor-element elementor-element-6b941356 e-flex e-con-boxed e-con e-parent\" data-id=\"6b941356\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-81d5654 wd-video-theme-style elementor-widget elementor-widget-video\" data-id=\"81d5654\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;youtube_url&quot;:&quot;https:\\\/\\\/youtube.com\\\/shorts\\\/3xxwpQdvZpw?feature=share&quot;,&quot;autoplay&quot;:&quot;yes&quot;,&quot;play_on_mobile&quot;:&quot;yes&quot;,&quot;show_image_overlay&quot;:&quot;yes&quot;,&quot;image_overlay&quot;:{&quot;url&quot;:&quot;https:\\\/\\\/aviaelectronics.com\\\/wp-content\\\/uploads\\\/2026\\\/05\\\/How-to-populate-a-d38999-shell.webp&quot;,&quot;id&quot;:35319,&quot;size&quot;:&quot;&quot;,&quot;alt&quot;:&quot;How to populate a d38999 shell&quot;,&quot;source&quot;:&quot;library&quot;},&quot;video_type&quot;:&quot;youtube&quot;,&quot;controls&quot;:&quot;yes&quot;}\" data-widget_type=\"video.default\">\n\t\t\t\t\t\t\t<div class=\"elementor-wrapper elementor-open-inline\">\n\t\t\t<div class=\"elementor-video\"><\/div>\t\t\t\t<div class=\"elementor-custom-embed-image-overlay\" style=\"background-image: url(https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/How-to-populate-a-d38999-shell.webp);\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<div class=\"elementor-custom-embed-play\" role=\"button\" aria-label=\"Play Video about How to populate a d38999 shell\" tabindex=\"0\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-eicon-play\" viewBox=\"0 0 1000 1000\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M838 162C746 71 633 25 500 25 371 25 258 71 163 162 71 254 25 367 25 500 25 633 71 746 163 837 254 929 367 979 500 979 633 979 746 933 838 837 929 746 975 633 975 500 975 367 929 254 838 162M808 192C892 279 933 379 933 500 933 621 892 725 808 808 725 892 621 938 500 938 379 938 279 896 196 808 113 725 67 621 67 500 67 379 108 279 196 192 279 108 383 62 500 62 621 62 721 108 808 192M438 392V642L642 517 438 392Z\"><\/path><\/svg>\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-684e879 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"684e879\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Populating a D38999 shell starts with choosing the correct insert, contacts, and crimp tools for your <a href=\"https:\/\/aviaelectronics.com\/en\/product-category\/circular-connectors\/mil-dtl-38999-series-iii-connectors\/\">mil-dtl-38999 Series connector<\/a>\u00a0and preparing your workspace to prevent debris and damage. Use the right contact size for your wire gauge, crimp each contact to the specified pull strength, and insert contacts until you feel the hard stop\u2014this ensures secure, vibration-resistant connections.<\/p><p>You will strip and crimp wires, inspect each crimp, and seat contacts into the shell while keeping grommets and seals clean to preserve environmental protection and EMI shielding. Follow the connector\u2019s insert arrangement and backshell thread standards to match accessories and maintain proper strain relief and sealing.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8141419 elementor-widget elementor-widget-image\" data-id=\"8141419\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"400\" height=\"300\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Crimping-Tool-400x300.webp\" class=\"attachment-medium size-medium wp-image-35358\" alt=\"\" srcset=\"\" data-srcset=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Crimping-Tool-400x300.webp 400w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Crimping-Tool-768x576.webp 768w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Crimping-Tool-16x12.webp 16w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Crimping-Tool-430x323.webp 430w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Crimping-Tool-700x525.webp 700w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Crimping-Tool-150x113.webp 150w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Crimping-Tool.webp 800w\" sizes=\"(max-width: 400px) 100vw, 400px\" title=\"\">\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Crimping Tool<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8adb59b elementor-widget elementor-widget-heading\" data-id=\"8adb59b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Crimp Contacts Specifications<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-9c3144b elementor-widget elementor-widget-wd_table\" data-id=\"9c3144b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"wd_table.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"wd-el-table-wrap wd-reset-all-last\">\n\t\t\t<table class=\"wd-el-table\">\n\t\t\t\t\t\t\t\t\t<thead class=\"text-left\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<tr class=\"wd-table-row elementor-repeater-item-4794926\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<th class=\"wd-table-cell elementor-repeater-item-4992332\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t\t<p>Contacts<\/p>\t\t\t\t\t\t\t\t<\/th>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<th class=\"wd-table-cell elementor-repeater-item-ae5c7f4\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t\t<p>Working Diamete<\/p>\t\t\t\t\t\t\t\t<\/th>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<th class=\"wd-table-cell elementor-repeater-item-58620b7\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t\t<p>Inside Dimension (MM)<\/p>\t\t\t\t\t\t\t\t<\/th>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<th class=\"wd-table-cell elementor-repeater-item-e183ae2\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t\t<p>Outer Diameter (MM)<\/p>\t\t\t\t\t\t\t\t<\/th>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<th class=\"wd-table-cell elementor-repeater-item-9e64ec4\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t\t<p>American standard cables (AWG)<\/p>\t\t\t\t\t\t\t\t<\/th>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<th class=\"wd-table-cell elementor-repeater-item-d60e075\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t\t<p>Removing and Installing Tools<\/p>\t\t\t\t\t\t\t\t<\/th>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<th class=\"wd-table-cell elementor-repeater-item-e3de7ae\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t\t<p>Crimping Tool<\/p>\t\t\t\t\t\t\t\t<\/th>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/tr>\n\t\t\t\t\t\t\t\t\t<tr class=\"wd-table-row elementor-repeater-item-c07f36d\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/tr>\n\t\t\t\t\t<\/thead>\n\t\t\t\t\n\t\t\t\t<tbody class=\"text-left\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<tr class=\"wd-table-row elementor-repeater-item-67e9bfb\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-4bfbed9\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>22D<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-f62f0fb\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>0.76<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-7d58d78\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>0.85<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-7c4c43e\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>1.20<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-6920bc7\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>28\u300126\u300124\u300122<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-8773be1\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>M81969\/14-01<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-7243513\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>YJQ-W7A<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/tr>\n\t\t\t\t\t\t\t\t<tr class=\"wd-table-row elementor-repeater-item-6daf185\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/tr>\n\t\t\t\t\t\t\t\t<tr class=\"wd-table-row elementor-repeater-item-5ee9d8c\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-01c0f3f\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>20#<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-a837825\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>1<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-b79a743\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>1.17<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-9407a51\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>1.78<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-17500fc\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>24\u300122\u300120<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-ac5a4f9\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>M81969\/14-10<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-77fd139\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>YJQ-W7A<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/tr>\n\t\t\t\t\t\t\t\t<tr class=\"wd-table-row elementor-repeater-item-fb6dc9b\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-34c2bcb\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>16#<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-9e139ca\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>1.6<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-5d0ff9e\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>1.68<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-e27a4c4\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>2.62<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-deb963d\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>20\u300118\u300116<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-2481ca3\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>M81969\/14-03<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-b3ec189\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>YJQ-W7A<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/tr>\n\t\t\t\t\t\t\t\t<tr class=\"wd-table-row elementor-repeater-item-8724d70\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-96a9f74\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>12#<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-ebe7311\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>2.4<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-eba6859\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>2.49<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-64eecbb\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>3.84<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-c7e3469\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>14\u300112<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-c6e49ac\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>M81969\/14-04<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-6f927cd\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>YJQ-W7A<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/tr>\n\t\t\t\t\t\t\t\t<tr class=\"wd-table-row elementor-repeater-item-3484012\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-8018acf\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>10#<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-daf74f0\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>3.15<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-dcb5120\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>3.40<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-fb66953\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>4.65<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-4aace9a\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>10<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-9945ba8\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>M81969\/14-05<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-0eb5d40\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>YJQ-W7A<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/tr>\n\t\t\t\t\t\t\t\t<tr class=\"wd-table-row elementor-repeater-item-93c60f5\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-fc82be5\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>08#<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-26ee764\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>3.6<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-cafca32\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>4.55<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-5eca049\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>6.4<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-a6ff8c6\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>8<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-980136c\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>M81969\/14-12<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<td class=\"wd-table-cell elementor-repeater-item-d6751fd\" colspan=\"1\" rowspan=\"1\">\n\t\t\t\t\t\t\t\t<p>YJQ-W7A<\/p>\t\t\t\t\t\t\t<\/td>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/tr>\n\t\t\t\t<\/tbody>\n\t\t\t<\/table>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ebe5d7c elementor-widget elementor-widget-heading\" data-id=\"ebe5d7c\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Key Takeaways<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3ffed60 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"3ffed60\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<ul>\n<li>Choose matching contacts, crimp tools, and insert arrangement for your D38999 shell.<\/li>\n<li>Clean the shell and seals, then crimp and insert contacts to the hard stop.<\/li>\n<li>Install the correct backshell and perform a pull and visual inspection for quality.<\/li>\n<\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-73a9631 elementor-widget elementor-widget-heading\" data-id=\"73a9631\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Fundamentals of D38999 Connectors<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4480442 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"4480442\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>You will learn the key specs, the main series and how older names map to current standards. This helps you pick the right shell, contact layout, and sealing level for your application.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2a2205d elementor-widget elementor-widget-heading\" data-id=\"2a2205d\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Overview of MIL-DTL-38999 Specifications<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-c514898 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"c514898\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p><a href=\"https:\/\/landandmaritimeapps.dla.mil\/Programs\/MilSpec\/ListDocs.aspx?BasicDoc=MIL-DTL-38999\" target=\"_blank\" rel=\"noopener\">MIL-DTL-38999<\/a> (formerly MIL-C-38999) defines high-performance circular connectors for harsh environments. You should expect requirements for shell sizes, contact types, current ratings, insulation resistance, and environmental sealing. The spec sets mechanical durability like mating cycles and vibration limits. It also covers materials and finishes for corrosion resistance.<\/p><p>Pay attention to contact retention and crimp versus solder terminations. The standard prescribes polarizing keyways and threaded or bayonet coupling styles. Electrical details include conductor size limits and contact arrangements that match specific shell sizes.<\/p><p>Compliance affects interchangeability and maintenance. When you select a connector, verify the exact MIL-DTL-38999 variant, shell finish, and class to ensure it meets temperature, altitude, and EMI needs for your system.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-7911cf4 elementor-widget elementor-widget-heading\" data-id=\"7911cf4\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">D38999 Series and Variants<\/h3>\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-f789235 e-con-full e-flex e-con e-child\" data-id=\"f789235\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t<div class=\"elementor-element elementor-element-8998b83 e-con-full e-flex e-con e-child\" data-id=\"8998b83\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-28e520e elementor-widget elementor-widget-image\" data-id=\"28e520e\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t\t<a href=\"https:\/\/aviaelectronics.com\/en\/product-category\/circular-connectors\/mil-dtl-38999-series-i-connectors\/\" target=\"_blank\">\n\t\t\t\t\t\t\t<img decoding=\"async\" width=\"400\" height=\"267\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-medium size-medium wp-image-35410\" alt=\"MIL-DTL-38999 series I II\" srcset=\"\" sizes=\"(max-width: 400px) 100vw, 400px\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-I-II-2-400x267.webp\" data-srcset=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-I-II-2-400x267.webp 400w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-I-II-2-768x512.webp 768w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-I-II-2-18x12.webp 18w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-I-II-2-430x287.webp 430w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-I-II-2-700x467.webp 700w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-I-II-2-150x100.webp 150w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-I-II-2.webp 1000w\" title=\"\">\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">MIL-DTL-38999 series I II<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-a22ce1b e-con-full e-flex e-con e-child\" data-id=\"a22ce1b\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-118efbd elementor-widget elementor-widget-image\" data-id=\"118efbd\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t\t<a href=\"https:\/\/aviaelectronics.com\/en\/product-category\/circular-connectors\/mil-dtl-38999-series-iii-connectors\/\" target=\"_blank\">\n\t\t\t\t\t\t\t<img decoding=\"async\" width=\"400\" height=\"267\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-medium size-medium wp-image-35411\" alt=\"MIL-DTL-38999 series III\" srcset=\"\" sizes=\"(max-width: 400px) 100vw, 400px\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-III-1-400x267.webp\" data-srcset=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-III-1-400x267.webp 400w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-III-1-768x512.webp 768w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-III-1-18x12.webp 18w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-III-1-430x287.webp 430w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-III-1-700x467.webp 700w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-III-1-150x100.webp 150w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/MIL-DTL-38999-series-III-1.webp 1000w\" title=\"\">\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">MIL-DTL-38999 series III<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2f634f2 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"2f634f2\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>D38999 connectors come in multiple series you must know: Series I, II, and III are the common MIL-DTL-38999 family lines, with Series III being the most used today. Series I and II were early military designs; they differ in coupling style and shell finishes. Series III uses a compact shell and improved seals, making it common for avionics and ground vehicles.<\/p><p>Manufacturers offer shell sizes (e.g., 9, 11, 17, 23) and contact arrangements that you select based on pin count and wire gauge. You will see options like jam nut, plug\/receptacle, and various rear accessories including backshells and grommets. Series IV and other derivatives exist in industry catalogs but confirm cross-reference to MIL-DTL-38999 before specifying for military contracts.<\/p><p>Match series to environment: use Series III for high sealing and compact layouts; consider Series I\/II only if legacy interchangeability is required.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2509a25 elementor-widget elementor-widget-heading\" data-id=\"2509a25\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Legacy Standards and Nomenclature<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-6e933b0 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"6e933b0\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Older documents and drawings may list MIL-C-38999 or D38999 without the \u201cMIL-DTL\u201d prefix. You should treat MIL-C-38999 as the legacy name; the current requirement is MIL-DTL-38999. Part numbers sometimes use legacy format, so decode them carefully to find series, shell size, and insert arrangement.<\/p><p>Manufacturers and catalogs may also use trade names or series identifiers (for example, Series III or 38999 Series III). When you read procurement specs, verify if they reference a particular military spec revision, because revisions change material or test criteria. Also watch for cross-reference tables that map old part numbers to current MIL-DTL-38999 part builders.<\/p><p>If you inherit equipment, inspect the connector body for stamped or molded markings showing series and shell size to confirm compatibility before mating or re-populating the shell.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-7db9db0 elementor-widget elementor-widget-heading\" data-id=\"7db9db0\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Selecting the Right Components<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-f4c60d4 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"f4c60d4\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Choose parts that match your application\u2019s space, mounting, and signal needs. Pay attention to shell size and style, insert arrangement, contact type, and the exact part number so your populated D38999 shell fits and performs as expected.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-710773d elementor-widget elementor-widget-heading\" data-id=\"710773d\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Choosing Shell Size and Style<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-146cd97 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"146cd97\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Pick the shell size that fits your cable bundle and panel cutout. Shell sizes range from large #8 to small #20 (and others); larger shells hold more contacts or larger power contacts. Match the shell size to the contact mix you need, not just cable diameter.<\/p><p>Select the shell style based on how you mount or mate the connector. Options include straight plug, receptacle, box mounting flange, wall mount flange, jam nut receptacle, and panel-mount styles. Series I\u2013IV have different backshell and coupling features; Series III is common for high-density, high-reliability uses.<\/p><p>Check if you need a specific finish or plating for corrosion resistance or EMI. Verify the full part number and part number breakdown to confirm shell size, style, material, and keying before ordering.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-914deb5 elementor-widget elementor-widget-heading\" data-id=\"914deb5\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Understanding Insert Arrangements<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-9047a8b color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"9047a8b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Insert arrangements define contact size, count, and physical layout inside the shell. Standard arrangements mix large power contacts and many small signal contacts; coax arrangements use specific positions for shielded contacts. Use the arrangement chart in the MIL-DTL-38999 spec or vendor datasheets to map wire-to-pin locations.<\/p>\n<p>Choose removable insert arrangements if you expect repair or rework. Removable crimp contacts let you extract and replace a single contact without replacing the insert. Fixed inserts can be denser but harder to service.<\/p>\n<p>Confirm polarization\/keying and orientation to avoid mismating. Note the insert\u2019s tooling requirements and the mating part\u2019s arrangement so pin numbers line up with your harness and schematic.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8e489fe elementor-widget elementor-widget-heading\" data-id=\"8e489fe\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Contact Types and Materials<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-51858b7 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"51858b7\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Decide between crimp type contacts, solder contacts, and removable crimp contacts. Crimp contacts give reliable mechanical and electrical connections and are common for field and production harnesses. Solder contacts suit low-volume or specialty uses.<\/p>\n<p>Pick contact materials for conductivity and durability: gold-plated copper alloys for signal contacts, tin or silver plating for power contacts, and stainless or beryllium copper for spring properties. Insulator material (often thermoplastic or PEEK) affects temperature and chemical resistance.<\/p>\n<p>Always check contact part numbers, tooling, and crimp specs. Match contact gender (pin or socket) to the mating part, and confirm the shell\u2019s insert arrangement and series (I\u2013IV) when ordering contacts and backshells.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ceedc2e elementor-widget elementor-widget-heading\" data-id=\"ceedc2e\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Preparation and Cleaning of the Shell<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-5ef6070 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"5ef6070\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Prepare the shell so contacts seat correctly and seals work as designed. Clean metal surfaces, check grommet fit, and remove any sealing plugs before insertion.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-47cecf7 elementor-widget elementor-widget-heading\" data-id=\"47cecf7\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Cleaning Methods<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2ce4c29 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"2ce4c29\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Start by removing any loose debris with a soft brush or compressed air at low pressure (20\u201330 psi). Hold the shell so you don\u2019t push particles into the grommet cavities. Use lint-free swabs dampened with isopropyl alcohol (70\u201399%) to wipe the interior surfaces, focusing on the contact cavities and the accessory thread.<\/p>\n<p>For stubborn contamination, use a mild solvent approved for aluminum or stainless steel. Apply solvent to a swab first\u2014never pour into the shell. Dry immediately with clean, dry swabs and allow 5\u201310 minutes for evaporation. Avoid ultrasonic cleaning if the grommet or sealing plugs remain installed, as this can trap fluid in cavities.<\/p>\n<p>If the shell has corrosion or plating damage, flag it and replace the shell rather than risking a faulty seal. Keep cleaned shells in anti-static, dust-free containers until you insert contacts.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4f9b2c5 elementor-widget elementor-widget-heading\" data-id=\"4f9b2c5\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Inspection and Static Prevention<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-e9866c4 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"e9866c4\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Inspect the shell visually and with a 10x magnifier for nicks, burrs, or foreign material in the grommet area. Check the grommet for tears, hardening, or displaced sealing plugs. Make sure any sealing plug is removed from contact cavities before insertion and stored so it doesn\u2019t contaminate other parts.<\/p><p>Control static by grounding yourself using a wrist strap tied to a verified earth point. Work on an ESD mat and keep relative humidity above 30% when possible. Handle contacts and the grommet by their edges; avoid touching contact mating surfaces. Finally, verify the accessory thread and backshell flange are free of chips to prevent damage to the grommet during backshell installation.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-e850cbb elementor-widget elementor-widget-heading\" data-id=\"e850cbb\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Wire Preparation and Contact Assembly: A Step-by-Step Guide<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-6fa69c1 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"6fa69c1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Proper wire preparation and contact assembly are critical to the reliability of high-performance connectors like the MIL-DTL-38999 series. In aerospace and defense applications, a single faulty crimp or poorly seated contact can lead to system failure. This guide outlines the standardized process for populating a connector shell.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ab9203f elementor-widget elementor-widget-image\" data-id=\"ab9203f\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"240\" height=\"426\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-large size-large wp-image-35432\" alt=\"Step 1.Strip the wire insulation.\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Step1.gif\" srcset=\"\" title=\"\">\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Step 1.Strip the wire insulation.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-38ce56a elementor-widget elementor-widget-heading\" data-id=\"38ce56a\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Step 1. Strip the Wire Insulation<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-b37f639 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"b37f639\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>The process begins with precision stripping. Use a thermal or mechanical stripper sized specifically for your wire gauge (AWG). The goal is to remove the insulation without nicking or flattening the internal conductor strands. Any damage to the strands will reduce the pull strength and increase electrical resistance.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-bad93b6 elementor-widget elementor-widget-image\" data-id=\"bad93b6\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"240\" height=\"426\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-large size-large wp-image-35427\" alt=\"Step 2.Insert the conductor into the contact wire barrel.\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Shep2.gif\" srcset=\"\" title=\"\">\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Step 2.Insert the conductor into the contact wire barrel.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-5381419 elementor-widget elementor-widget-heading\" data-id=\"5381419\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">2. Insert the Conductor into the Contact Wire Barrel<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-19d25b5 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"19d25b5\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Once stripped, the exposed conductor should be inserted into the wire barrel of the contact. Ensure that all strands are gathered inside the barrel; &#8220;birdcaging&#8221; (strands splaying outside the barrel) is a primary cause of short circuits. You should be able to see the conductor through the inspection hole in the contact barrel to verify full insertion.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1569ff6 elementor-widget elementor-widget-image\" data-id=\"1569ff6\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"240\" height=\"426\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-large size-large wp-image-35428\" alt=\"Step 3.Place the contact into the crimp tool&#039;s positioner and crimp firmly.\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Shep3.gif\" srcset=\"\" title=\"\">\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Step 3.Place the contact into the crimp tool's positioner and crimp firmly.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ce86121 elementor-widget elementor-widget-heading\" data-id=\"ce86121\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">3. Crimp the Contact Firmly<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-062128f color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"062128f\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Place the contact into the positioner of a calibrated crimp tool, such as the M22520 series. The positioner ensures the crimp happens at the precise height required by the contact specification. Squeeze the handles firmly until the cycle is complete\u2014controlled-cycle tools will not release until the proper pressure has been applied, ensuring a gas-tight connection.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-9a80ad9 elementor-widget elementor-widget-image\" data-id=\"9a80ad9\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"240\" height=\"426\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-large size-large wp-image-35429\" alt=\"Step 4.Place the crimped wire into the insertion tool.\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Shep4.gif\" srcset=\"\" title=\"\">\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Step 4.Place the crimped wire into the insertion tool.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-45c6449 elementor-widget elementor-widget-heading\" data-id=\"45c6449\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">4. Load the Crimped Wire into the Insertion Tool<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-6978bd2 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"6978bd2\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Most military-grade connectors use a dual-ended tool: the Red\/White end is typically for Insertion, and the Blue\/White end is for Extraction. Place the wire into the longitudinal slot of the insertion tool, resting the tip of the tool against the rear shoulder of the contact.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-59e5164 elementor-widget elementor-widget-image\" data-id=\"59e5164\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"240\" height=\"426\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-large size-large wp-image-35430\" alt=\"Step 5.Insert the contact into the corresponding cavity and push until it reaches the hard stop.\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Shep5.gif\" srcset=\"\" title=\"\">\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Step 5.Insert the contact into the corresponding cavity and push until it reaches the hard stop.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1ef7c26 elementor-widget elementor-widget-heading\" data-id=\"1ef7c26\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">5. Insert into the Cavity and Reach the Hard Stop<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-e27f5f6 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"e27f5f6\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Align the contact with the correct cavity in the connector&#8217;s insert arrangement. Push the tool straight into the grommet. You should feel a distinct click or &#8220;click-feel&#8221; as the internal retention tangs snap over the contact shoulder. This is known as reaching the Hard Stop.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d7b7240 elementor-widget elementor-widget-image\" data-id=\"d7b7240\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"240\" height=\"426\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-large size-large wp-image-35431\" alt=\"Step 6.Repeat the above steps and perform a pull test to ensure secure retention.\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Shep6.gif\" srcset=\"\" title=\"\">\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Step 6.Repeat the above steps and perform a pull test to ensure secure retention.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-253cf29 elementor-widget elementor-widget-heading\" data-id=\"253cf29\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">6. Verification and Pull Test<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-715e320 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"715e320\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Repeat the process for all required pins. After each insertion, perform a tactile pull test. Lightly tug on the wire (typically 3\u20135 lbs of force) to ensure the retention mechanism is fully engaged. If the wire slides out, the retention tangs may be damaged or the contact was not pushed far enough.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3605d50 elementor-widget elementor-widget-image\" data-id=\"3605d50\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"240\" height=\"426\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-large size-large wp-image-35433\" alt=\"Step 7.Use the removal end of the tool, insert it into the cavity, and pull the wire to extract the contact.\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/Shep7.gif\" srcset=\"\" title=\"\">\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Step 7.Use the removal end of the tool, insert it into the cavity, and pull the wire to extract the contact.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2853497 elementor-widget elementor-widget-heading\" data-id=\"2853497\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">7. Contact Extraction for Rework<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ee93bd6 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"ee93bd6\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>If you need to change a pin or repair a wire, use the removal end (extraction side) of the tool. Slide the tool into the cavity from the rear until it disengages the retention tangs. Once the tangs are spread, gently pull the wire and tool together to extract the contact from the shell.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-285b80d elementor-widget elementor-widget-heading\" data-id=\"285b80d\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Backshells, Accessories, and Environmental Protection<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-54202ed color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"54202ed\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Pick the right backshell, clamp, and finishing to match your connector, cable diameter, and environment. Choose between threaded or bayonet coupling, specify materials and finishes, and plan for EMI grounding and strain relief during assembly.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-489ddbd elementor-widget elementor-widget-heading\" data-id=\"489ddbd\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Selecting and Installing Backshells<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-495e1f6 elementor-widget elementor-widget-image\" data-id=\"495e1f6\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t\t<a href=\"https:\/\/aviaelectronics.com\/en\/product-category\/backshells\/\" target=\"_blank\">\n\t\t\t\t\t\t\t<img decoding=\"async\" width=\"300\" height=\"300\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-medium size-medium wp-image-30861\" alt=\"Circular Mil Backshells\" srcset=\"\" sizes=\"(max-width: 300px) 100vw, 300px\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-300x300.webp\" data-srcset=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-300x300.webp 300w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-800x800.webp 800w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-150x150.webp 150w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-768x768.webp 768w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-12x12.webp 12w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-430x430.webp 430w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-700x700.webp 700w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-1000x1000.webp 1000w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/04\/Circular-Mil-BackshellsAccessories-e1779592959210.webp 500w\" title=\"\">\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Circular Mil Backshells<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-682e2dc color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"682e2dc\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Choose a backshell that matches the D38999 series and shell size. For Series II and III, confirm the thread type (triple-start threaded coupling or bayonet coupling) and mating interface before ordering. Match the backshell style\u2014straight, 45\u00b0, or 90\u00b0\u2014to your routing needs to avoid kinking or excess bend radius.<\/p><p>Select the correct cable clamp or M85049-style adapter (M85049\/21, M85049\/38, M85049\/39) for your cable diameter. Use the specified torque for the shell size when fitting the backshell. If you use an adapter, ensure it seats fully and that any rotatable coupling is locked per the manufacturer\u2019s instruction.<\/p><p>Pick a finish that resists your environment: olive drab cadmium or electroless nickel for corrosion resistance, or black zinc nickel where non-reflective finish is needed. Verify material compatibility with the connector\u2019s finish to avoid galvanic corrosion.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-50195e2 elementor-widget elementor-widget-heading\" data-id=\"50195e2\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">EMI\/RFI Shielding and Grounding<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-245ec43 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"245ec43\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Ensure continuous shielding from cable braid to connector shell. Use a shield termination backshell or conductive braid termination (banding or clamp) to close the gap between the cable shield and the connector shell.<\/p>\n<p>Choose M85049-compatible banding or a clamp with conductive gasket where a full perimeter contact is required. For high-performance EMI control, use a backshell with built-in EMI\/RFI shield sock or conductive braid adapter. Tighten band clamps to the recommended torque and inspect the braid capture for full contact.<\/p>\n<p>Establish a low-impedance path to ground. Use a conductive gasket or bonding strap between the backshell and the connector shell. If your assembly will see vibration, lock the EMI termination with a split ring or set screw per the backshell spec.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-b8c1e0f elementor-widget elementor-widget-heading\" data-id=\"b8c1e0f\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Environmental Sealing and Strain Relief<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d597821 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"d597821\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Seal the transition area to protect against moisture, dust, and fluids. Choose an environmental backshell with integrated sealing or use heat-shrink boots and shrink-molded parts sized to the cable. Use M85049-qualified components where applicable for military environmental requirements.<\/p>\n<p>Provide strain relief sized for the cable and load. Use clamp-style backshells, swing-arm strain reliefs, or band-in-a-can assemblies to prevent conductor-to-contact stress. Secure the clamp so it bears mechanical load, not the cable jacket alone.<\/p>\n<p>Verify sealing materials and finishes are compatible with temperature range and fluids expected in service. Perform a visual and torque inspection after assembly and re-check the seal and clamp after any maintenance.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-fae3a42 elementor-widget elementor-widget-heading\" data-id=\"fae3a42\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Final Inspection and Quality Assurance<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-fcc79ef color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"fcc79ef\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>You must verify mechanical fit, electrical function, and environmental sealing before release. Confirm contact retention, wiring accuracy, continuity, insulation resistance, and correct backshell torque.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-e7cfb06 elementor-widget elementor-widget-heading\" data-id=\"e7cfb06\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Testing Populated Shells<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-dc49a1b color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"dc49a1b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Perform a visual and mechanical check first. Inspect contact alignment for D38999 Series inserts and confirm each contact is fully seated to the hard stop. Check grommets and seals for tears or foreign debris.<\/p>\n<p>Run electrical tests next. Use continuity checks for every contact and a contact-to-contact insulation resistance test at specified voltages. For mixed-power arrangements, perform hi-pot (dielectric) testing per your spec. Use a calibrated pull-test tool to verify crimp and retention forces meet the contact size requirements.<\/p>\n<p>Do functional EMI\/ground continuity tests on assemblies using D38999\/33 shell types when shielding is required. If the connector must be environmentally sealed, perform a pressure or IP67-style leak test after backshell installation and torque to specified Nm.<\/p>\n<p>Record test equipment IDs, settings, and operator initials. Hold failed units for rework and retest; scrap only if repairs cannot restore original spec.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d7d702e elementor-widget elementor-widget-heading\" data-id=\"d7d702e\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Labeling and Documentation<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3918f50 elementor-widget elementor-widget-image\" data-id=\"3918f50\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t\t<a href=\"https:\/\/aviaelectronics.com\/en\/product-category\/caps\/\" target=\"_blank\">\n\t\t\t\t\t\t\t<img decoding=\"async\" width=\"300\" height=\"300\" src=\"https:\/\/aviaelectronics.com\/wp-content\/themes\/woodmart\/images\/lazy.svg\" class=\"attachment-medium size-medium wp-image-35092\" alt=\"D38999\/33W15N-main\" srcset=\"\" sizes=\"(max-width: 300px) 100vw, 300px\" data-src=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/D3899933W15N-main-300x300.webp\" data-srcset=\"https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/D3899933W15N-main-300x300.webp 300w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/D3899933W15N-main-150x150.webp 150w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/D3899933W15N-main-768x768.webp 768w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/D3899933W15N-main-12x12.webp 12w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/D3899933W15N-main-430x430.webp 430w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/D3899933W15N-main-700x700.webp 700w, https:\/\/aviaelectronics.com\/wp-content\/uploads\/2026\/05\/D3899933W15N-main.webp 800w\" title=\"\">\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">D38999\/33W15N-main<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ed19285 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"ed19285\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Mark each assembly with a durable label showing part number, serial number, lot code, and assembly date. For D38999 parts include the full MIL-DTL-38999 prefix and shell type (for example D38999\/33) so downstream users can confirm series and shell variation.<\/p><p>Attach an inspection tag that lists performed tests and measured values: continuity, insulation resistance, hi-pot voltage, pull test force, and torque values. Store digital records in your traceability system with linked photos of critical areas (contact seating, backshell thread engagement, seal installation).<\/p><p>Include a copy of the assembly drawing and the crimp tool\/positioner ID used for each contact size. Keep retention of records per your contract or MIL-spec requirement so audits and failure investigations can trace materials and processes.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-6c714fd elementor-widget elementor-widget-heading\" data-id=\"6c714fd\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Frequently Asked Questions<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-420ea50 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"420ea50\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>This section answers common, practical questions on tools, sizes, keying, part numbers, and sources. You will find clear steps, measurement tips, and where to get official layouts and datasheets.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-c6dafec elementor-widget elementor-widget-heading\" data-id=\"c6dafec\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">What tools and steps are needed to install contacts into a circular connector shell correctly?<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-751c633 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"751c633\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Use a calibrated crimp tool that matches your contact and the M22520 standard for crimp dies when required. Also have insertion\/extraction tools, a wire stripper sized to the contact barrel, a torque wrench for backshells, and a clean lint-free work area.<\/p>\n<p>Strip the wire to the contact\u2019s specified length. Crimp to the contact by following the tool and contact maker\u2019s settings, then visually inspect the crimp and perform a light pull test (typically 3\u20135 lbs) to confirm retention.<\/p>\n<p>Place the contact into the insert until you feel a hard stop or hear the retention click. Use the proper insertion tool to avoid damaging the grommet or retention features. If a contact won\u2019t seat, remove it with the extraction tool and inspect the contact and cavity.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-fd0cbfe elementor-widget elementor-widget-heading\" data-id=\"fd0cbfe\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">How do I choose the correct shell size and insert arrangement for my application?<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-b31d846 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"b31d846\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Start by listing the number of signal, power, and coax contacts you need and the maximum wire gauges and currents. Match those needs to insert arrangements (e.g., 09-35, 13-35) that support the contact sizes you require.<\/p>\n<p>Check the shell\u2019s physical envelope and accessory thread to ensure backshell and panel compatibility. Also confirm environmental needs (temperature, sealing, EMI) so you select the correct material and plating for weight, corrosion resistance, and shielding.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-da59897 elementor-widget elementor-widget-heading\" data-id=\"da59897\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">How can I read the shell size letter and convert it to the corresponding size number?<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1b1c9bf color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"1b1c9bf\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Locate the shell code printed or stamped on the connector body; it may be a letter (A\u2013J) or a numeric size (09\u201325). Use the standard conversion: A = 09, B = 11, C = 13, D = 15, E = 17, F = 19, G = 21, H = 23, J = 25.<\/p>\n<p>If you don\u2019t find a marking, measure the connector max diameter across the shell and compare to a manufacturer shell size chart to confirm the numeric size.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-b8cfbfb elementor-widget elementor-widget-heading\" data-id=\"b8cfbfb\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">What is the correct method to identify keying, clocking, and polarization before inserting contacts?<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4029d50 color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"4029d50\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Inspect the connector face for keyway shapes, polarized flats, or guarded pins that force a single orientation. Match mating connectors visually and by part numbers that include polarization or keying codes.<\/p>\n<p>Use clock position markings (if present) to confirm orientation for multi-pin groups. If you\u2019re unsure, dry-fit the unpopulated shells or use a known mating plug to verify alignment before inserting contacts.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d7afe4b elementor-widget elementor-widget-heading\" data-id=\"d7afe4b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">How do I interpret a MIL-style connector part number to confirm shell, insert, and contact type?<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-545d50f color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"545d50f\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Break the part number into its standard fields: series, shell size, insert arrangement, shell style\/finish, and contact type. Refer to the manufacturer\u2019s part-number decoding guide to map each code to its meaning.<\/p>\n<p>Confirm contact sizes and insert pattern by cross-checking the arrangement code (for example, \u201c13-35\u201d indicates shell and insert pattern). When in doubt, request the manufacturer\u2019s datasheet or a print showing the insert layout.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-abe77d1 elementor-widget elementor-widget-heading\" data-id=\"abe77d1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Where can I find reliable datasheets, catalogs, or PDF guides for insert layouts and pin numbering?<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-b5c769e color-scheme-inherit text-left elementor-widget elementor-widget-text-editor\" data-id=\"b5c769e\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Go to major connector manufacturers\u2019 sites (Amphenol, Glenair, TE\/ITT) for official datasheets and printable insert layout PDFs. Manufacturer catalogs include insert drawings, pin numbering, shell dimensions, and accessory thread data.<\/p>\n<p>Also consult trusted distributor portals and military specification documents for MIL-DTL-38999. Verify the document revision and match the series (I, II, III, or IV) before using pin layouts for wiring.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>https:\/\/youtube.com\/shorts\/3xxwpQdvZpw?feature=share Populating a D38999 shell starts with choosing the correct insert, contacts, and crimp tools for your mil-dtl-38999 Series connector\u00a0and<\/p>\n","protected":false},"author":1,"featured_media":35319,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[876],"tags":[],"class_list":["post-35310","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-product-news"],"_links":{"self":[{"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/posts\/35310","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/comments?post=35310"}],"version-history":[{"count":1,"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/posts\/35310\/revisions"}],"predecessor-version":[{"id":37147,"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/posts\/35310\/revisions\/37147"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/media\/35319"}],"wp:attachment":[{"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/media?parent=35310"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/categories?post=35310"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/aviaelectronics.com\/en\/wp-json\/wp\/v2\/tags?post=35310"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}