Assembly Manuals Connector 38-Way 15498537 - 2 - Rev.02

Connector 38-way
Assembly / Disassembly
REV 02
May 2009
EUCD Assembly Manuals

Connector 38-way - assembly at harness plant
TABLE OF CONTENTS
Components (exploded view) ............................................................................................................ 3

List of components ............................................................................................................................. 4
View of versions .................................................................................................................................. 5
ASSEMBLY SEQUENCE: ...................................................................................................................... 6
step 1: inserting MCP 1,5 ........................................................................................... 6
step 2: inserting MCP 2.8 ........................................................................................... 7
step 3: inserting MCP 4.8 ............................................................................................ 8
step 4: activate Secondary Lock .............................................................................. 9
step 5: assemble Cover ............................................................................................. 10
step 6: locking Cover .............................................................................................. 11
step 7: strapping leads .............................................................................................. 12
step 8: performing test ............................................................................................ 13
step 9: holder specifications ..................................................................................... 14
DISASSEMBLY SEQUENCE: ............................................................................................................. 15
step D-1: removing strap ........................................................................................... 16
step D-2: rotating Lever ............................................................................................. 17
step D-3: unlocking Cover ........................................................................................ 18
step D-4: removing Cover ......................................................................................... 19
step D-5: unlocking Secondary Lock ....................................................................... 20
step D-6: removing MCP 4.8 .................................................................................... 21
step D-7: removing MCP 2.8 ..................................................................................... 22
step D-8: removing MCP 1.5 ..................................................................................... 23
Tools ..................................................................................................................................................... 24
Revisions ............................................................................................................................................ 25
The information contained in these assembly instructions is subject to alteration without prior notice and does not represent any
obligation on the part of DELPHI. All information is correct at the time of releasing. Reprinting or translation is not permitted
without written permission from DELPHI. Copyright 2009 DELPHI. All rights reserved.
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

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EXPLODED VIEW
COVER
DELPHI PART-NO. 15498543
FORD PART-NO. 6G9T-14N003-VZA
MCP 4,8 Female Terminal
MCP 1,5 or CTS 1,5

Female Terminal
CONNECTOR 38-WAY
DELPHI PART-NO. 15498535
FORD PART-NO. 6G9T-14A464-VZA

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LIST OF COMPONENTS
Component:
Delphi
PART-NO.
FORD
PART-NO.
Cover
15498543
6G9T-14N003-VZA
Connector 38-way
assembled
15498535
6G9T-14A464-VZA
amount
MCP 1,5 or CTS 1.5 Female Terminal
max. 34
max. 2
max. 2
Attention:
All plastic components must be stored minimum 24 hours, in the temperature of min +18C,
before further assembly steps are taken. This is necessary to avoid breakage of hinge or snap
elements.

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13670756
13670755
13662622
13670757
13655518
VIEW OF VERSIONS

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ASSEMBLY
CONNECTOR 38-WAY
INSERTING MCP 1,5
24
12
37
26
2
Insert MCP 1,5 Female Terminals into the Receptacle Housing 38-way
according to the harness drawing and the specified code.
ASSEMBLY
Step 1:
14
Step 1 completed.

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CONNECTOR 38-WAY
INSERTING MCP 2,8
38
25
ASSEMBLY
Step 2:
Step 2 completed.

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CONNECTOR 38-WAY
INSERTING MCP 4,8
13
1
ASSEMBLY
Step 3:
Step 3 completed.

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CONNECTOR 38-WAY
ACTIVATE SECONDARY LOCK
Step 4:
Push the Secondary Lock to the end position using tool PN 10806565 .
Attention! There is no possibility to connect together Male and Female
Connectors without correctly locked Secondary Lock.
Secondary Lock
(opposite to Lever)
Lever
ASSEMBLY
Slots released by finalpositined Secondary

Lock
Step 4 completed.

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CONNECTOR 38-WAY
ASSEMBLE COVER
Orient and comb wires in appropriate direction. Hitch one side of the Cover
on the Receptacle Housing 38-way.
ASSEMBLY
Step 5:
Hitched point
Step 5 completed.

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CONNECTOR 38-WAY
LOCKING COVER
Step 6:
Lock the other side of the Cover by rotating it about the hitched point
until four locking arms are correctly closed.
ASSEMBLY
Locks on both sides

of the Receptacle Housing 38-way
are correctly closed
Step 6 completed.

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CONNECTOR 38-WAY
STRAPPING LEADS
Strap leads.
ASSEMBLY
Step 7:
Step 7 completed.

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CONNECTOR 38-WAY
ASSEMBLY
ELECTRICAL TEST ON RING OUT BOARD
Step 6
Perform electrical test according to Ring Out Board specifications.

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CONNECTOR 38-WAY
ASSEMBLY
ELECTRICAL TEST ON RING OUT BOARD
Holder specifications.

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DISASSEMBLY
CONNECTOR 38-WAY
REMOVING STRAP
Remove Strap.
DISASSEMBLY
Step D-1:
Step D-1 completed.

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CONNECTOR 38-WAY
ROTATING LEVER
Move the Lever to the middle position - about 90 degrees from horizontal
position.
DISASSEMBLY
Step D-2:
Step D-2 completed.

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CONNECTOR 38-WAY
UNLOCKING COVER
Unlock one side of the Cover.
DISASSEMBLY
Step D-3:
Step D-3 completed.

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CONNECTOR 38-WAY
REMOVING COVER
Remove Cover completely.
DISASSEMBLY
Step D-4:
Step D-4 completed.

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CONNECTOR 38-WAY
UNLOCK. SECONDARY LOCK
Push the Secondary Lock to the pre-assembled position using tool PN

10806565 .
Secondary Lock
(Lever on the same side)
Slots blocked by
opened Secondary
Lock
DISASSEMBLY
Step D-5:
Lever
Step D-5 completed.

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CONNECTOR 38-WAY
REMOVING MCP 4,8
Locate Terminal tangs at the front of the cavity. Insert (operation 1) the tool
NO. 10714843 straight into the channel of cavity, deflect tangs to unseat
the Terminal and gently pull on the cable to remove (operation 2) MCP 4,8
Female Terminal from the Receptacle Housing 38-way.
DISASSEMBLY
Step D-6:
Step D-6 completed.

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CONNECTOR 38-WAY
REMOVING MCP 2,8
DISASSEMBLY
Step D-7:
Step D-7 completed.

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CONNECTOR 38-WAY
REMOVING MCP 1,5
DISASSEMBLY
Step D-8:
Step D-8 completed.

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TOOLS
Item
Function
Tool PN.
Disassembly tool for MCP 1,5 Female Terminals
10803860
Disassembly tool for MCP 2,8 and MCP 4,8 Female Terminals
10714843
Disassembly tool for Secondary Lock
10806565
These tools is available at

Sales & Service
Sylvia Kirberg
phone: +49 202 291 4458
fax:
+49 202 291 4567

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REVISIONS
Revision
Change description
Date
REV 01
Initial Edition
May 05, 2009

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Assembly Manuals Connector 38-Way 15498537 - 2 - Rev.02

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Connector 38-way

EUCD Assembly Manuals

Components (exploded view) ............................................................................................................ 3

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

MCP 4,8 Female Terminal

MCP 1,5 or CTS 1,5

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

MCP 1,5 or CTS 1.5 Female Terminal

MCP 2,8 Female Terminal

MCP 4,8 Female Terminal

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

INSERTING MCP 1,5

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Slots released by finalpositined Secondary

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Locks on both sides

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

ELECTRICAL TEST ON RING OUT BOARD

Perform electrical test according to Ring Out Board specifications.

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

ELECTRICAL TEST ON RING OUT BOARD

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Step D-1 completed.

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009

EUCD Assembly Manuals

Step D-2 completed.

Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317

REV 02 May 05, 2009