MIL-DTL-25955A
3.4.2 Insert design and construction. Inserts shall be designed and constructed with suitable sections
and radii such that they will not readily chip, crack, or break in assembly or in normal service. Inserts
shall be one-piece construction (monoblock) and shall not be hollowed out for weight saving purposes.
Pin entry openings and chamfers on socket insert faces shall be as small as practicable to prevent cross
plugging of alternate insert position connectors. Socket inserts shall provide adequate protection against
a pin contacting a socket before the mating pair of connectors has been polarized.
3.4.2.1 Contact insertion and removal. Pin and socket contacts shall be removable for wire connecting
purposes. The method for securing the contacts in the insert shall be such that the contacts may be
inserted in and removed from their normal position in the insert with no special tools other than a tool with
tip dimensions as specified on figure 2.
B
C
D
E
G
A
F
± .015
± .010
± .002
± .005
± .005
max
max
.156
.250
.062
.040
.090
.085
.031
(3.962)
(6.350)
(1.575)
(1.016)
(2.286)
(2.159)
(.787)
NOTE: Dimensions are in inches.
FIGURE 2. Contact tool tip.
3.4.2.2 Contact alignment. Inserts for socket contacts shall be designed such that individual sockets
shall have an overall side play of .005 inch (0.13 mm) minimum to facilitate self alignment of mating
contacts.
3.4.2.3 Contact arrangement. Contact arrangement in inserts shall be as specified by the connector
PIN and in accordance with the applicable detail document. The design of any arrangement shall be
such that the pin insert of one arrangement cannot be engaged with the socket insert of another
arrangement.
3.4.2.4 Insert positioning. Positive provisions shall be made to position all inserts in shells. Inserts
shall be keyed to prevent rotation with respect to shells. The clearance or difference between insert
keyway and shell key dimensions shall be not greater than .020 inch (0.51 mm). Sideplay or the
difference between the shell inner diameter and the insert outer diameter shall be not greater than
.013 inch (3.30 mm).
3.4.2.5 Alternate insert positions. Inserts shall be supplied rotated from the normal position as
indicated in the applicable documents if so specified in the connector PIN.
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