MIL-DTL-38999

Features and Application

Series I

Features and Application Closed-Entry Socket Insert – Hard dielectric socket face
has lead-in chamfers for positive alignment of pins (even
partially bent within pre-established limits) with sockets.
38999 S I

MIL-DTL-38999 Series I is a bayonet coupling subminiture

configuration with high contact density, ideal for smaller wire Interfacial Pin Insert Seal – Raised moisture barriers
gauge, general-purpose applications. These environment- around each pin, which mate into lead-in chamfers of hard
resisting connectors are 100% “scoop-proof.” Pins are face socket insert, provide individual contact sealing.
recessed in elongated shells to prevent the possibility of Interfacial seal is never touched by service tools.
bending contacts when plugs are scooped into the mating
receptacles. Elastomer Wire Sealing Grommet – Sealing over a wide
range of wire diameters is assured by a triple wire seal in
This family of connectors is offered in 5 receptacle-mounting each cavity at the rear of the connector.
styles. They include square flange receptacles, for both front
and rear panel (wall) mounting; square flange receptacles, for Superior Contact Stability – Rear release crimp contact
both front and rear box mounting; and jam nut receptacles system features a stamped beryllium-copper retaining clip
which incorporate “O” ring seals, designed for rear panel captivated by molded-in shoulders of each contact cavity in
“D” hole mounting. the insulator. A rear-inserted M81969 plastic tool expands
the tines beyond the shoulder, releasing the contact.
Standard plugs provide RFI protection by incorporating a
continuous strip of attached grounding fingers attenuating Shell Polarization – Alternate key/keyway positions prevent
interference up to 1 GHz. cross mating of adjacent connectors having identical insert
arrangement.
Fifty-seven insert arrangements per MIL-STD-1560 are
tooled and qualified to MIL-DTL-38999 Series I, utilizing
2 to 128 contacts. Contacts come in sizes 22M, 22D, 20, 16,
12, and 8 (coax and twinax), terminating wire sizes from 28
gauge to 12 gauge including coaxial cable.

These connectors are available in wide range of shell materials

and finishes. Aluminum shells are offered in electroless nickel,
olive drab cadmium and bright cadmium. Other finishes
such as anodic and zinc cobalt are available upon request to
commercial callouts only. In addition, we offer passivated
stainless steel shells with standard environment-resisting
inserts (commercial callouts only), and for highly corrosive
environments, nickel-aluminum-bronze shells with standard
environment-resisting inserts (commercial callouts only).

Universal I/R Tool – A single, expendable plastic tool is

used for both insertion and removal of contacts.

Scoop-Proof Design – Recessed pins in elongated shells

minimize the possibility for contact damage. In a blind
mating application, mating shells cannot “scoop” the pins,
and cause a shorting or bending of contacts.

www.conesys.com – 3 – sales@aero-electric.com
 MIL-DTL-38999
Performance Specifications
Series I

Performance Specifications Shielding Effectiveness

RFI and EMI attenuation at the specified frequencies meet
Operating Temperature Range the requirements of MIL-DTL-38999.
• RFI shielding effectiveness of mated connectors with

38999 S I
Finish B: -65°C to +175°C (-85°F to +347°F)
Finish F: -65°C to +200°C (-85°F to +392°F RFI backshells is measured in a triaxial radio frequency
Finish A: -65°C to +150°C (-85°F to +302°F) leakage fixture.
• EMI shielding effectiveness is measured at the interface
Material and Plating Data (Finish) of mated connectors and tested by the mode-stirred
B – aluminum shell, olive drab cadmium over nickel base technique specified in method 3008 of MIL-STD-1344.
F – aluminum shell, electroless nickel finish
A – aluminum shell, silver to light iridescent yellow color Shock and Vibration Requirements
(bright) cadmium over electroless nickel Wired, mated connectors shall not be damaged, nor shall
there be a current interruption longer than one microsecond
Corrosion Resistance when subjected to the following:
Finishes A and B withstand 500-hour salt spray.
Finish F withstands 48-hour salt spray. Standard Shock
Mated connectors withstand a pulse of approximate half
Durability sine wave of 300 G ± 15 percent magnitude with duration of
Minimum of 500 mating cycles 3 ± 1 milliseconds applied in three axes per MIL-STD-1344,
method 2004.
Environmental Seal
Wired, mated connectors with specified accessories at- High Impact Shock
tached, shall meet the altitude-immersion test specified in When mounted as specified in MIL-S-901, grade A, a drop
MIL-DTL-38999. of a 400 lb. Hammer from 1 foot, 3 feet and 5 feet applied to
connector in three axes, totaling nine impacts.
Fluid Resistance
Connectors resist specified immersions in MIL-PRF-7808, Vibration
MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol Mated connectors, with proper accessories, withstand the
25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5), following vibration levels:
SAE-AMS1424 Type I, and other solvents and cleaning agents. • Sine Vibration per MIL-STD-202, method 204, test
condition G.
Shell-to-Shell Conductivity • Random Vibration per MIL-STD-1344, method 2005,
• Finish F = 1.0 millivolt maximum potential drop test condition V and test condition VI, Letter “J” at ambi-
• Finishes A and B = 2.5 millivolts maximum potential drop ent temperature.

Voltage Rating
Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 100,000 Ft.
Service Rating AC (RMS) DC V RMS V RMS V RMS V RMS
M 400 550 1300 550 350 200
N 300 450 1000 400 260 200
I 600 850 1800 600 400 200
II 900 1250 2300 800 500 200

exactly what peak voltages, switching currents, transients,

Note: The establishment of electrical safety factors is left
etc., can be expected in a particular circuit.
entirely to the designer, as he is in the best position to know

www.conesys.com – 4 – sales@aero-electric.com
 MIL-DTL-38999
Part Number Development
Series I

Military and Aero-Electric Part Number Development

Mil. Prefix MS 27467 T 13 B 35 P A

Aero Prefix AE 167 T 13 B 35 P A -340
38999 S I

Shell Type
27466 = Front, wall mount receptacle = 166 (Aero p/n)
27467 = RFI grounding plug = 167 (Aero p/n)
27468 = Jam nut receptacle = 168 (Aero p/n)
27496 = Front, box mount receptacle = 196 (Aero p/n)
27505 = Rear, box mount receptacle = 105 (Aero p/n)
27656 = Rear, wall mount receptacle = 156 (Aero p/n)
Class
T = With acc. thread (MS27466, MS27467, MS27468 & MS27656)
E = Same as T in line above but is not approved for new design
(E-nut is not included)
= No acc. thread, box mount (MS27496 & MS27505)
Shell Size
9, 11, 13, 15, 17, 19, 21, 23 or 25
Finish (Material & Plating)
A = Aluminum shell, silver to light iridescent yellow color (bright) cadmium over nickel base
B = Aluminum shell, olive drab cadmium over electroless nickel base
F = Aluminum shell, electroless nickel finish
S = Stainless steel shell, passivated (Aero p/n only)
Insert Arrangement
See page 19 thru 21
Contact Style
P = Pin
S = Socket
A = Pin connector less pins (with intent to use non-standard pin contacts)
B = Socket connector less sockets (with intent to use non-standard socket contacts)
Polarization (Keying)
N = Normal (Omitted in part number)
A, B, C, or D (B & C keyways are not available in shell size 9)
Modification (applies to Aero part numbers only)
01 = Less contacts (is not marked on the part)
340 = Connector kitted with M85049/27-XXX E-nut
341 = Connector kitted with M85049/49-2-XXX straight clamp
342 = Connector kitted with M85049/47XXX right angle clamp
Consult factory for other modifications

Note 1: Each connector is furnished with contacts unless Note 2: Proper part number marking has no “0” in front
ordered less contacts (L/C) as follows: One spare contact for of single digit shell size (9) and no “0” in front of single digit
inserts requiring 1 through 26 of each contact and two spares layout. Example of each: J MS27466T9B35S and
for inserts with more than 26 contacts and a minimum of J MS27466T11B5S. In both, “N” for normal is omitted. In
one sealing plug up to 10% of the number of contacts. Spare addition, J or JAN must now be marked in front of the MS
Coax and Twinax contacts are not supplied. One insertion/ part number.
removal tool for each contact size is also included.

www.conesys.com – 5 – sales@aero-electric.com
 MS27466
Front, Wall Mounting Receptacle
AE166

Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof

1.323(33.60)
MAX
A

38999 S I
D F
MASTER KEYWAY
B .219(5.56)
MIN. FULL THREAD

.060(1.52)
MAX GROMMET EXTENSION

H
E MAX
GROMMET

J ACCESSORY TEETH
G ACCESSORY THREAD
4X MINOR KEYWAYS
4x  C
BLUE COLOR BAND

Page 5 Completed Part Number

Page 15 Contacts, Sealing Plugs and Tools
Pages 19–21 Insert Arrangements
Page 4 Performance Specifications
Pages 16-18 Insert Availability and Contact Information
Page 13 Polarization

A B ØC D ØE F G ØH J
+.010 +.25 +.000 +.00 +.001 +.03 +.015 +.38 Accessory No. of
Shell ±.020 ±.51 (TP) -.005 -.13 -.005 -.13 -.005 -.13 -.000 -.00 Thread Maximum Teeth
Size inch mm inch mm inch mm inch mm inch mm inch mm UNEF-2A inch mm
9 .938 23.83 .719 18.26 .128 3.25 .632 16.05 .572 14.53 .085 2.16 7/16-28 .299 7.59 12
11 1.031 26.19 .812 20.62 .128 3.25 .632 16.05 .700 17.78 .085 2.16 9/16-24 .427 10.85 16
13 1.125 28.58 .906 23.01 .128 3.25 .632 16.05 .850 21.59 .085 2.16 11/16-24 .541 13.74 20
15 1.219 30.96 .969 24.61 .128 3.25 .632 16.05 .975 24.77 .085 2.16 13/16-20 .666 16.92 24
17 1.312 33.32 1.062 26.97 .128 3.25 .632 16.05 1.100 27.94 .085 2.16 15/16-20 .791 20.09 28
19 1.438 36.53 1.156 29.36 .128 3.25 .632 16.05 1.207 30.66 .085 2.16 1-1/16-18 .897 22.78 32
21 1.562 39.67 1.250 31.75 .128 3.25 .602 15.29 1.332 33.83 .115 2.92 1-3/16-18 1.022 25.96 36
23 1.688 42.88 1.375 34.93 .147 3.73 .602 15.29 1.457 37.01 .115 2.92 1-5/16-18 1.147 29.13 40
25 1.812 46.02 1.500 38.10 .147 3.73 .602 15.29 1.582 40.18 .115 2.92 1-7/16-18 1.272 32.31 44

www.conesys.com – 6 – sales@aero-electric.com
 MS27656
Rear, Wall Mounting Receptacle
AE156

Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof

1.350 (34.29)
MAX

A
38999 S I

D F
MASTER KEYWAY .219 (5.56)
B MIN FULL THREAD

.060 (1.52)
MAX GROMMET EXTENSION

H
E MAX
GROMMET

J ACCESSORY TEETH
G ACCESSORY THREAD
4X MINOR KEYWAYS
4x  C
BLUE COLOR BAND

Page 5 Completed Part Number

Page 15 Contacts, Sealing Plugs and Tools
Pages 19–21 Insert Arrangements
Page 4 Performance Specifications
Pages 16-18 Insert Availability and Contact Information
Page 13 Polarization Note: See page 14 for panel thickness.

A B ØC D ØE F G ØH J
+.010 +.25 +.000 +.00 +.001 +.03 +.015 +.38 Accessory No. of
Shell ±.020 ±.51 (TP) -.005 -.13 -.005 -.13 -.005 -.13 -.000 -.00 Thread Maximum Teeth
Size inch mm inch mm inch mm inch mm inch mm inch mm UNEF-2A inch mm
9 .938 23.83 .719 18.26 .128 3.25 .820 20.83 .572 14.53 .085 2.16 7/16-28 .299 7.59 12
11 1.031 26.19 .812 20.62 .128 3.25 .820 20.83 .700 17.78 .085 2.16 9/16-24 .427 10.85 16
13 1.125 28.58 .906 23.01 .128 3.25 .820 20.83 .850 21.59 .085 2.16 11/16-24 .541 13.74 20
15 1.219 30.96 .969 24.61 .128 3.25 .820 20.83 .975 24.77 .085 2.16 13/16-20 .666 16.92 24
17 1.312 33.32 1.062 26.97 .128 3.25 .820 20.83 1.100 27.94 .085 2.16 15/16-20 .791 20.09 28
19 1.438 36.53 1.156 29.36 .128 3.25 .820 20.83 1.207 30.66 .085 2.16 1-1/16-18 .897 22.78 32
21 1.562 39.67 1.250 31.75 .128 3.25 .790 20.07 1.332 33.83 .115 2.92 1-3/16-18 1.022 25.96 36
23 1.688 42.88 1.375 34.93 .147 3.73 .790 20.07 1.457 37.01 .115 2.92 1-5/16-18 1.147 29.13 40
25 1.812 46.02 1.500 38.10 .147 3.73 .790 20.07 1.582 40.18 .115 2.92 1-7/16-18 1.272 32.31 44

www.conesys.com – 7 – sales@aero-electric.com
 MS27496
Front, Box Mounting Receptacle
AE196

Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof

1.104(28.04)
MAX
A

38999 S I
MASTER KEYWAY
D F
B

.060(1.52)
MAX GROMMET EXTENSION

H
E MAX G
GROMMET MAX

.312(7.93)
4X MINOR KEYWAYS
MAX
4x  C
BLUE COLOR BAND

Page 5 Completed Part Number

Page 15 Contacts, Sealing Plugs and Tools
Pages 19–21 Insert Arrangements
Page 4 Performance Specifications
Pages 16-18 Insert Availability and Contact Information
Page 13 Polarization

A B ØC D ØE F ØG ØH
+.010 +.25 +.000 +.00 +.001 +.03 +.015 +.38
Shell ±.020 ±.51 (TP) -.005 -.13 -.005 -.13 -.005 -.13 -.000 -.00 Maximum Maximum
Size inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm
9 .938 23.83 .719 18.26 .128 3.25 .632 16.05 .572 14.53 .085 2.16 .469 11.91 .299 7.59
11 1.031 26.19 .812 20.62 .128 3.25 .632 16.05 .700 17.78 .085 2.16 .594 15.09 .427 10.85
13 1.125 28.58 .906 23.01 .128 3.25 .632 16.05 .850 21.59 .085 2.16 .719 18.26 .541 13.74
15 1.219 30.96 .969 24.61 .128 3.25 .632 16.05 .975 24.77 .085 2.16 .844 21.44 .666 16.92
17 1.312 33.32 1.062 26.97 .128 3.25 .632 16.05 1.100 27.94 .085 2.16 .969 24.61 .791 20.09
19 1.438 36.53 1.156 29.36 .128 3.25 .632 16.05 1.207 30.66 .085 2.16 1.078 27.38 .897 22.78
21 1.562 39.67 1.250 31.75 .128 3.25 .602 15.29 1.332 33.83 .115 2.92 1.203 30.56 1.022 25.96
23 1.688 42.88 1.375 34.93 .147 3.73 .602 15.29 1.457 37.01 .115 2.92 1.328 33.73 1.147 29.13
25 1.812 46.02 1.500 38.10 .147 3.73 .602 15.29 1.582 40.18 .115 2.92 1.453 36.91 1.272 32.31

www.conesys.com – 8 – sales@aero-electric.com
 MS27505
Rear, Box Mounting Receptacle
AE105

Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof

1.100(27.94)
MAX
A
38999 S I

D F
MASTER KEYWAY
B

.060(1.52)
MAX GROMMET EXTENSION

H G
E MAX MAX
GROMMET

4X MINOR KEYWAYS
4x  C
BLUE COLOR BAND

Page 5 Completed Part Number

Page 15 Contacts, Sealing Plugs and Tools
Pages 19–21 Insert Arrangements
Page 4 Performance Specifications
Pages 16-18 Insert Availability and Contact Information
Note: See page 14 for panel thickness.
Page 13 Polarization

A B ØC D ØE F ØG ØH
+.010 +.25 +.000 +.00 +.001 +.03 +.015 +.38
Shell ±.020 ±.51 (TP) -.005 -.13 -.005 -.13 -.005 -.13 -.000 -.00 Maximum Maximum
Size inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm
9 .938 23.83 .719 18.26 .128 3.25 .820 20.83 .572 14.53 .085 2.16 .547 13.89 .299 7.59
11 1.031 26.19 .812 20.62 .128 3.25 .820 20.83 .700 17.78 .085 2.16 .656 16.66 .427 10.85
13 1.125 28.58 .906 23.01 .128 3.25 .820 20.83 .850 21.59 .085 2.16 .828 21.03 .541 13.74
15 1.219 30.96 .969 24.61 .128 3.25 .820 20.83 .975 24.77 .085 2.16 .953 24.21 .666 16.92
17 1.312 33.32 1.062 26.97 .128 3.25 .820 20.83 1.100 27.94 .085 2.16 1.078 27.38 .791 20.09
19 1.438 36.53 1.156 29.36 .128 3.25 .820 20.83 1.207 30.66 .085 2.16 1.203 30.56 .897 22.78
21 1.562 39.67 1.250 31.75 .128 3.25 .790 20.07 1.332 33.83 .115 2.92 1.328 33.73 1.022 25.96
23 1.688 42.88 1.375 34.93 .147 3.73 .790 20.07 1.457 37.01 .115 2.92 1.453 36.91 1.147 29.13
25 1.812 46.02 1.500 38.10 .147 3.73 .790 20.07 1.582 40.18 .115 2.92 1.578 40.08 1.272 32.31

www.conesys.com – 9 – sales@aero-electric.com
 MS27468
Jam Nut Receptacle
AE168

Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof

E 1.308 (33.22)
MAX
.920 (23.37) B

38999 S I
.910 (23.11)
.615 (15.62)
MASTER KEYWAY .598 (15.19)
.060 (1.52) MAX
GROMMET EXTENSION

K ØA ØC
FLAT MAX
GROMMET

G No. OF TEETH
ØD 4X MINOR KEYWAYS F ACCESSORY THREAD
BLUE COLOR BAND
3X BAYONET PINS J THREAD
EQUALLY SPACED "O"-RING
BLUE COLOR BAND
HEX NUT
PER MS3186
PANEL THICKNESS
.125(3.18)
.062(1.57)

Page 5 Completed Part Number

Page 15 Contacts, Sealing Plugs and Tools
Pages 19–21 Insert Arrangements
Page 4 Performance Specifications
Pages 16-18 Insert Availability and Contact Information
Page 13 Polarization

ØA B ØC ØD E F G J K
+.001 +.03 +.011 +.28 Accessory No. of Jam Nut Thread Flat
Shell -.005 -.13 -.010 -.25 Maximum ±.016 ±.41 ±.016 ±.41 Thread Teeth Class 2A ±.005 ±.13
Size inch mm inch mm inch mm inch mm inch mm UNEF- 2A inch mm
9 .572 14.53 .109 2.77 .299 7.59 1.188 30.18 1.062 26.97 7/16-28 12 11/16-24UNEF .650 16.51
11 .700 17.78 .109 2.77 .427 10.85 1.375 34.93 1.250 31.75 9/16-24 16 13/16-20UNEF .750 19.05
13 .850 21.59 .109 2.77 .541 13.74 1.500 38.10 1.375 34.93 11/16-24 20 1-20UNEF .937 23.80
15 .975 24.77 .109 2.77 .666 16.92 1.625 41.28 1.500 38.10 13/16-20 24 1-1/8-18UNEF 1.061 26.95
17 1.100 27.94 .109 2.77 .791 20.09 1.750 44.45 1.625 41.28 15/16-20 28 1-1/4-18UNEF 1.186 30.12
19 1.207 30.66 .140 3.56 .897 22.78 1.938 49.23 1.812 46.02 1-1/16-18 32 1-3/8-18UNEF 1.311 33.30
21 1.332 33.83 .140 3.56 1.022 25.96 2.062 52.37 1.938 49.23 1-3/16-18 36 1-1/2-18UNEF 1.436 36.47
23 1.457 37.01 .140 3.56 1.147 29.13 2.188 55.58 2.062 52.37 1-5/16-18 40 1-5/8-18UNEF 1.561 39.65
25 1.582 40.18 .140 3.56 1.272 32.31 2.312 58.72 2.188 55.58 1-7/16-18 44 1-3/4-18UNS 1.686 42.82

www.conesys.com – 10 – sales@aero-electric.com
 MS27467
RFI Grounding Plug
AE167

Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof

 F MAX. 1.294
(32.87)
COUPLING NUT MAX
MASTER KEY
38999 S I

RFI STRIP E ACCESSORY THREAD

.060(1.52) GROMMET
MAX EXTENSION

A
MIN C
MAX
GROMMET

D No. OF TEETH

.219(5.56) MIN
4 MINOR KEYS FULL THREAD

BLUE COLOR BAND

Page 5 Completed Part Number

Page 15 Contacts, Sealing Plugs and Tools
Pages 19–21 Insert Arrangements
Page 4 Performance Specifications
Pages 16-18 Insert Availability and Contact Information
Page 13 Polarization

ØA ØC D E ØF
No. of Accessory Thread
Shell Minimum Maximum Teeth Class 2A Maximum
Size inch mm inch mm inch mm
9 .417 10.59 .299 7.59 12 7/16-28UNEF .859 21.82
11 .545 13.84 .427 10.85 16 9/16-24UNEF .984 24.99
13 .657 16.69 .541 13.74 20 11/16-24UNEF 1.156 29.36
15 .782 19.86 .666 16.92 24 13/16-20UNEF 1.281 32.54
17 .907 23.04 .791 20.09 28 15/16-20UNEF 1.406 35.71
19 1.012 25.70 .897 22.78 32 1-1/16-18UNEF 1.516 38.51
21 1.137 28.88 1.022 25.96 36 1-3/16-18UNEF 1.641 41.68
23 1.262 32.05 1.147 29.13 40 1-5/16-18UNEF 1.766 44.86
25 1.387 35.23 1.272 32.31 44 1-7/16-18UNEF 1.891 48.03

www.conesys.com – 11 – sales@aero-electric.com
 M38999/9
Dummy Stowage Receptacle
AE109

Dummy Stowage Receptacle, Bayonet Coupling

38999 S I
Part Number Configuration
MIL. Prefix M38999 9/ XX B
Aero Prefix AE10 9- XX B
Shell Type
9 = receptacle, dummy stowage, bayonet coupling

Shell Size
9 THRU 25 (Note: single digit for shell size 9)

Material Finish
B = Aluminum, Cadmium Olive Drab
A = Aluminum, Bright Cadmium over Nickel base (Aero p/n only)
F = Aluminum shell, Electroless Nickel finish (Aero p/n only)
S = Stainless steel shell, passivated (Aero p/n only)
BN = Aluminum, Black Nickel (Aero p/n only)
BZ = Bronze (Aero p/n only)

ØA K ØT J
SHELL M S
+.001 +.015 +.010 +.010
SIZE ±.010 ±.020
-.005 -.000 -.005 -.015
9 .572 .085 .727 .128 .938 .567
11 .700 .085 .727 .128 1.031 .567
13 .850 .085 .727 .128 1.125 .567
15 .975 .085 .727 .128 1.219 .567
17 1.100 .085 .727 .128 1.312 .567
19 1.207 .085 .727 .128 1.438 .567
21 1.332 .115 .697 .128 1.562 .567
23 1.457 .115 .697 .147 1.688 .567
25 1.582 .115 .697 .147 1.812 .567

www.conesys.com – 12 – sales@aero-electric.com
 MIL-DTL-38999
Polarization
Series I

Keying Positions
38999 S I

NORMAL
C° MASTER
KEYWAY

A° B°
N°

D°

5°

DATUM F

Notes:
1. Mating face of receptacle shown (plug is opposite).
2. The master keyway (key) has various positions relative
to DATUM F; the minor keyways (keys) remain fixed as
shown. In the Normal position, the master keyway (key)
is at 95° from DATUM F.
3. The angles for a given connector are the same whether it
contains pin or socket inserts.
4. The insert arrangement does not rotate relative to master
keyway (key).

Keying Positions
BSC
Shell
Size N° A° B° C° D°
9 95 77 – – 113
11 95 81 67 123 109
13 95 75 63 127 115
15 95 74 61 129 116
17 95 77 65 125 113
19 95 77 65 125 113
21 95 77 65 125 113
23 95 80 69 121 110
25 95 80 69 121 110

www.conesys.com – 13 – sales@aero-electric.com
 MIL-DTL-38999 Series I
Flange and Jam Nut Receptacles
Panel Cutouts

Panel Cutouts

FLANGE MOUNT JAM NUT MOUNT

38999 S I
D MAX .125(3.18)
PANEL THICKNESS .062(1.57)
PANEL THICKNESS

4x C B
MIN

=F
A

Note 1: Flange Mounting Dimensions (Ø B cutout and Note 2: D MAX includes mounting hardware.
D MAX) listed only for back of panel mounting (MS27505
and MS27656).

Flange and Jam Nut Mounting Dimensions

A ØB ØC D E ØF
+.000* +.00* +.010 +.25
Shell (TP) Minimum ±.005 ±.13 Maximum -.010 -.25 -.000 -.00
Size inch mm inch mm inch mm inch mm inch mm inch mm
9 .719 18.26 .656 16.66 .128 3.25 .234 5.94 .657* 16.70* .693 17.60
11 .812 20.62 .796 20.22 .128 3.25 .234 5.94 .771 19.59 .825 20.96
13 .906 23.01 .922 23.42 .128 3.25 .234 5.94 .955 24.26 1.010 25.65
15 .969 24.61 1.047 26.59 .128 3.25 .234 5.94 1.085 27.56 1.135 28.83
17 1.062 26.97 1.219 30.96 .128 3.25 .234 5.94 1.210 30.73 1.260 32.01
19 1.156 29.36 1.297 32.94 .128 3.25 .234 5.94 1.335 33.91 1.385 35.18
21 1.250 31.75 1.422 36.12 .128 3.25 .204 5.18 1.460 37.08 1.510 38.35
23 1.375 34.93 1.547 39.29 .154 3.91 .204 5.18 1.585 40.26 1.635 41.53
25 1.500 38.10 1.672 42.47 .154 3.91 .193 4.90 1.710 43.43 1.760 44.70
* Tolerance ± .10mm (±.004”)

www.conesys.com – 14 – sales@aero-electric.com
 MIL-DTL-38999
Contacts, Tools and Seal Plugs
Series I

Contacts, Plastic Insertion/Removal Tools and Seal Plugs

Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Contact Size Type Military No. Military No. Military No. Military No.
38999 S I

22D Power/Signal M39029/58-360 M39029/56-348

M81969/14-01
22M* Power/Signal M39029/58-361 M39029/56-349 MS27488-22-1
22* Power/Signal M39029/58-362 M39029/56-350 —
20 Power/Signal M39029/58-363 M39029/56-351 MS27488-20-1 M81969/14-10
16 Power/Signal M39029/58-364 M39029/56-352 MS27488-16-1 M81969/14-03
12 Power/Signal M39029/58-365 M39029/56-353
12 Coax Coax M39029/28-211 M39029/75-416 MS27488-12-1 M81969/14-04
12 Coax Coax M39029/102-558 M39029/103-559
8 Coax Coax M39029/60-367 M39029/59-366 MS27488-8-1 M81969/14-06
8 Twinax Twinax M39029/90-529 M39029/91-530 MS27488-8-1 M81969/14-12

Crimping and Metal Insertion/Extraction Tools

Contact Size/
Crimp Tool Positioner Positioner Insertion Tool Extraction Tool
Type For Pin Contacts For Socket Contacts Metal Metal
Military No. Military No. Military No. Military No. Military No.
22D, 22M* M22520/2-01 M22520/2-09 M22520/2-07 M81969/8-01 M81969/8-02
22* M22520/2-01 M22520/2-09 M22520/2-07 M81969/8-03 M81969/8-04
M22520/1-01 M22520/1-04 M22520/1-04
20 M81969/8-05 M81969/8-06
M22520/2-01 M22520/2-10 M22520/2-10
16 M22520/1-01 M22520/1-04 M22520/1-04 M81969/8-07 M81969/8-08
12 M22520/1-01 M22520/1-04 M22520/1-04
12 Coax Inner M22520/2-01 M22520/2-34 M22520/2-34 M81969/8-09 M81969/8-10
12 Coax Outer M22520/31-01 M22520/31-02 M22520/31-02
8 Coax Inner M22520/2-01 M22520/2-31 M22520/2-31
M22520/5-05 M22520/5-05 M81969/8-13** M81969/8-14
8 Coax Outer M22520/5-01
Die Closure B Die Closure B
8 Twinax Center M22520/2-01 M22520/2-37 M22520/2-37
8 Twinax Outer — —
M22520/5-01 M22520/5-200 M22520/5-200
& Intermediate

Contact and Wire Data

Test Current Voltage Crimp Well Data Wire Range Finished Wire Ø Range
DC Test Max. Drop Well Dia. Minimum Well Dept Minimum Maximum
Contact Size Amps Millivolts inch inch mm AWG mm2 inch mm inch mm
22D 5.0 73 .0345 ±.0010 .141 3.58 28-22 .08-.33 .030 .76 .054 1.37
22M* 3.0 45 .028 ±.001 .141 3.58 28-24 .08-.20 .030 .76 .050 1.27
22* 5.0 73 .0365 ±.0010 .141 3.58 26-22 .13-.33 .034 .86 .060 1.52
20 7.5 55 .047 ±.001 .209 5.31 24-20 .20-.52 .040 1.02 .083 2.11
16 13.0 49 .067 ±.001 .209 5.31 20-16 .52-1.31 .065 1.65 .109 2.77
12 23.0 42 .100 ±.002 .209 5.31 14-12 2.08-3.31 .097 2.46 .142 3.61

* Inactive for new design Note 2: Size 12 coax contacts purchased in bulk.
** Insertion tool is not required.
Note 3: Size 8 coax contacts are used with M17/095-RG180
Note 1: Test Current and Maximum Voltage Drop when cable, while size 8 Twinax contacts are used with
tested with silver-plated wire at 25°C. M17/176-00002 cable.

www.conesys.com – 15 – sales@aero-electric.com
 MIL-DTL-38999
Contact Installation Instructions
Series I

Contact Installation 3. Place the correct insertion tool on the contact so that the
Instructions wire runs along the groove in the tool. (Tool tip will butt
against the shoulder.) Hold the plug or receptacle body

38999 S I
firmly.
Crimping Contacts
1. Select the appropriate crimp tool and ensure that the 4. Beginning with a center cavity, insert the contact into
proper crimp head positioner is used. the insulator with a slow, even pressure until the contact
snaps into position. Make sure the contact and tool are
2. Cycle the tool to be sure the indentors are open. held perpendicular to the face of the insert during the
contact installation or the grommet could be damaged.
3. Determine the correct selector setting for the wire size
from the data plate on the positioner (turret head 4.1 If contacts are not inserted all the way prior to
assembly) and set the selector knob on the crimp tool removing insertion tool, do not try to reinsert the
to match. insertion tool. Instead, remove the contact and try
again; otherwise reinserting the insertion tool may
4. Place the contact, mating end first, into the tool. damage the inside of the contact cavity.

5. Insert the stripped wire into the hollow end of the 5. Remove tool and check the face of the connector for
contact. Be sure the wire is inserted as far as it will go. proper contact installation. Proper installation may also
be checked by pulling back lightly on the wire to make
6. Close the tool completely to crimp. Unless the tool is sure the contact is properly seated.
closed completely, the tool will not release the contact.
Completion
7. Remove the crimped contact from the tool. Check the After all the cavities have been filled, slide the hardware back
inspection hole to verify that the wire is fully inserted. into position on the connector and tighten.

Insertion of Contacts Extraction of Contacts (Rework)

1. Before inserting the contacts, unscrew the accessories 1. Slide the hardware back over the wire bundle.
(clamps, backshells or adapters) from rear of plug or
recep­tacle. Slide the hardware over the wire bundle in 2. Select the appropriate tool. Place the wire into the
the proper order for reassembly after all the contacts extraction tool of the pin or socket.
are inserted.
3. Slowly slide the extraction tool down wire into the
2. To assist insertion of contacts, lubricate insulator contact cavities until the tool tip bottoms against the
(grommet) cavities with isopropyl alcohol. Alcohol will contact shoulder, expanding the clip retaining tines. Hold
evaporate and will not leave a conductive film. Caution: the wire firmly in the tool and pull the wired contact and
Never use any lubricant other than isopropyl alcohol. tool straight out of the rear of the insulator.

Insertion/Removal
Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner
Tool
22D M39029/58-360 M39029/56-348 M22520/2-01 M22520/2-09 M22520/2-07 M81969/14-01
22M M39029/58-361 M39029/56-349 M22520/2-01 M22520/2-09 M22520/2-07 M81969/14-01
22 M39029/58-362 M39029/56-350 M22520/2-01 M22520/2-09 M22520/2-07 M81969/14-01
M22520/1-01 M22520/1-04 Red M22520/1-04 Red
20 M39029/58-363 M39029/56-351 M81969/14-10
M22520/2-01 M22520/2-10 M22520/2-10
20 M39029/58-364 M39029/56-352 M22520/1-01 M22520/1-04 Blue M22520/1-04 Blue M81969/14-03
12 M39029/58-365 M39029/56-353 M22520/1-01 M22520/1-04 Yellow M22520/1-04 Yellow M81969/14-04
For coax and twinax contacts refer to instructions that are supplied with contacts.

www.conesys.com – 16 – sales@aero-electric.com
 MIL-DTL-38999 Series I
Insert Availability and Contact Information
per MIL-STD-1560

Insert Availability and Contact Information

Insert
Aero-Electric Service Total Quantity of Contacts
Arrangement Status No. of (by Size)
38999 S I

Series I QPL’d Tooled Rating Contacts 22D 22M 22 20 16 12 10 8

9-6* Yes Yes M 6 6
9-35 Yes Yes M 6 6
9-98 Yes Yes I 3 3
11-2 Yes Yes I 2 2
11-4 Yes Yes I 4 4
11-5 Yes Yes I 5 5
11-13* Yes Yes M 13 13
11-35 Yes Yes M 13 13
11-98 Yes Yes I 6 6
11-99 Yes Yes I 7 7
13-4 Yes Yes I 4 4
13-8 Yes Yes I 8 8
13-22* Yes Yes M 22 22
13-35 Yes Yes M 22 22
13-98 Yes Yes I 10 10
15-5 Yes Yes II 5 5
15-15 Yes Yes I 15 14 1
15-18 Yes Yes I 18 18
15-19 Yes Yes I 19 19
15-35 Yes Yes M 37 37
15-37* Yes Yes M 37 37
15-97 Yes Yes I 12 8 4
17-6 Yes Yes I 6 6
17-8 Yes Yes II 8 8
17-26 Yes Yes I 26 26
17-35 Yes Yes M 55 55
17-55* Yes Yes M 55 55
17-99 Yes Yes I 23 21 2
19-11 Yes Yes II 11 11
19-28 Yes Yes I 28 26 2
19-30 Yes Yes I 30 29 1
19-32 Yes Yes I 32 32
19-35 Yes Yes M 66 66
19-66* Yes Yes M 66 66

See next page for Shell Sizes 21 thru 25 layouts. * Not approved for new design. Tooled and qualified but their
separate pictorials are not shown on pages 19 thru 21, as they
are the same as corresponding (-35) layouts that take the same
quantity of 22D contacts, but are supplied with 22M contacts
instead.

www.conesys.com – 17 – sales@aero-electric.com
 MIL-DTL-38999 Series I
Insert Availability and Contact Information
per MIL-STD-1560

Insert Availability and Contact Information (continued)

Aero-Electric Service Total Quantity of Contacts
Insert
Arrangement Status No. of (by Size)

38999 S I
Series I QPL’d Tooled Rating Contacts 22D 22M 22 20 16 12 10 8
21-1* Yes Yes M 79 79
21-11 Yes Yes I 11 11
21-16 Yes Yes II 16 16
21-35 Yes Yes M 79 79
21-39 Yes Yes I 39 37 2
21-41 Yes Yes I 41 41
21-48** N/A Yes I 4 4 (Power)
21-75 Yes Yes Twinax 4 4 (Twinax)
23-1* Yes Yes M 100 100
23-2*** Yes Yes M 85 85
23-21 Yes Yes II 21 21
23-32 Yes Yes I 32 32
23-35 Yes Yes M 100 100
23-53 Yes Yes I 53 53
23-55 Yes Yes I 55 55
25-1* Yes Yes M 128 128
25-4 Yes Yes I 56 48 8
25-19 Yes Yes I 19 19
25-24 Yes Yes I 24 12 12
25-29 Yes Yes I 29 29
25-35 Yes Yes M 128 128
25-43 Yes Yes I 43 23 20
25-46 Yes Yes I, Coax 46 40 4 2 (Coax)
25-61 Yes Yes I 61 61

* Not approved for new design. Tooled and qualified but their separate
pictorials are not shown on pages 19 thru 21, as they are same as
corresponding (-35) layouts that take the same quantity of 22D contacts,
but are supplied with 22M contacts instead.

** 21-48 layout is not to MIL-STD-1560. It is tooled and intended for

commercial use only.

*** Not approved for new design. Pictorial is shown on page 20.

www.conesys.com – 18 – sales@aero-electric.com
 MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series I Connectors

Insert Arrangements Views

38999 S I

1
C A D A E A 10 2
B A 11
5 1
6 9 3
B
4 2 8 13 4
3 12
C B D B 5
C 7 6

9-35 9-98 11-2 11-4 11-5 11-35

6 # 22D, M 3 # 20, I 2 # 16, I 4 # 20, I 5 # 20, I 13 # 22D, M

A A
A G A 14 1 H B

21 15 G
F A D B C
E F B G H B J
F K
E B 22
D C F D
E C
D C C D
E

11-98 11-99 13-4 13-8 13-35 13-98

6 # 20, I 7 # 20, I 4 # 16, I 8 # 20, I 22 # 22D, M 10 # 20, I

L A L A B
A M 1 K A
K B
A M K M N B L N P C
31 J L B
E B J R N C 21
J T U P C K U V R D H

H P D H S R D J T S E C
G M D
G E G F E H F
D C G
F F E

15-5 15-15 15-18 15-19 15-35 15-97

5 # 16, II 1 # 16, 14 # 20, I 18 # 20, I 19 # 20, I 37 # 22D, M 4 # 16, 8 # 20, I

A 17 32 A
A B 10 25 40 R B
E A R
4 S T
S T C 47 P C
G B P
a b 1 Y Z U
D F B N D 53 D
U N
55 X V
M Z V E 3
F H C M E
L c
Y W F W
9 52 L
K X G F
E D 16 46 G
C J H 24 31 39 K
J H

17-6 17-8 17-26 17-35 17-99

6 # 12, I 8 # 16, II 26 # 20, I 55 # 22D, M 2 # 16, 21 # 20, I

www.conesys.com – 19 – sales@aero-electric.com
 MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series I Connectors

Insert Arrangements Views

S A
T A T A
R
A S B B S B
J U P d T U
d V e V
R C c U C R C
N

38999 S I
K B e
H W f W
c e
P D b D P d j D
V g
X M g f X
b
N E N c h E
G C Y a W
E Y
L
L a
X b
M F Z M F
Z K F a Z
F D Y
L G L G
K J G K J
E J H H

19-11 19-28 19-30 19-32

11 # 16, II 2 # 16, 26 # 20, I 1 # 16, 29 # 20, I 32 # 20, I

L 1
25 34
43 J A
17 A
10 51
4 58
K 51
M B 31
H
1 64 K B S
J N C

G 21
L 79 71
3 66 P
C H 61
R
9 63
D
F
16 57 41
24 50 11
33 42 D G E
E F

19-35 21-11 21-16

21-35
66 #22D, M 11 # 12, I 16 # 16, II
79 # 22D, M

W A A
W B
V B
X V C
C X
U Y j Y D A
j
k U
i Z D k Z
T i D A
m E
h m T s a
r
S a E h t F
R F S n b
g b r C B
q G D B
P n g p
c G q c
R H
f p
N d H f
e P e d
M J C
J
N K
L K M L

21-48**
21-75
21-39 21-41 4 # 8 Power, I
4 # 8 Twinax, Twinax
2 # 16, 37 # 20, I 41 # 20, I

29 48 N
39 N A
20 58 A 25 46 67
12 67 M 16 35 56 77
M b P 8 86
5 P B R B
75 1 94
a
L L h c S 2
1 82 W R C 95
C
Z 3 96
X g d T
i 4 97
98
V S
K D K
Y D
f 5 99
4 85 e U
U T J 6
J 10 0
11 81 X V E
E
W 7
19 74 15 93
28 47 66 H F H F 24 45 66 85
38 57 G G 34 55 76

23-2* 23-21 23-32 23-35

85 # 22, M 21 # 16, II 32 # 20, I 100 # 22D, M

* Inactive for new design.

** Not MIL-STD-1560 layout (not QPL’d.).

www.conesys.com – 20 – sales@aero-electric.com
 MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series I Connectors

Insert Arrangements Views

a A
Z B
Y b
S U w C M A B
A A X c
T T v D
R B B
V u GG x d
n n
38999 S I

U W E L
m C m p W C N P C
P p V S y e
AA AA q X t HH
k q W k
BB D Y D V FF F
z r z BB r K
GG JJ z f U V R D
h GG CC j s
N HH X R CC s Z
s E HH E U EE G
FF DD LL g
M y P y r
EE F DD F KK
g Y i a T AA H
FF EE DD
x t x t h
L N H q J T E
f w u Z w b S BB J S
u CC k
e v a M g v c G p
K G
d f d R n m K F
b H
J c H L e H P L G
K J N M

23-53 23-55 25-4

25-19
55 # 20, I 55 # 20, I 8 # 16, 48 # 20, I
19 # 12, I

36 48 59 71 82 Z
A A 25 94 Y A
P B 15 105 B
R B X
8 115 C
N S T n p a
R C P 1 122 W
C D
b c U V m w q b
Y S E
M D N D
Z f U F
a d V 125 x r c
4

T k v
X T G
M E
a e s d
L S h u t
E Z W H
W U L F 7 R
V Y X g f e J
K F 14 121
K G P K
24 11 4
J G 35 104 N
H J H L
47 5870 81 93 M

25-24 25-29 25-35 25-43

12 # 12, 12 # 16, I 29# 16, I 128 # 22D, M 20 # 16, 23 # 20, I

A Z
W Y A
B a b
V t X u B
u X c
s Y C t v d
U AA W GG C
v w
r s HH e
T Z FF D
D V x
q a NN JJ
r f
p PP y E
S E U
b EE
T q F
n z w MM KK g
R c F z
m P DD LL G
d S h
P y x G CC AA
k e R n BB H
i
N g f j
h H P m J
k
M J N K
L K M L

25-46 25-61
40 # 20, 4 # 16, 2 # 8 Coax, I / Coax 61 # 20, I

www.conesys.com – 21 – sales@aero-electric.com