48V Two-Way Pass-Through Header

Sealed 48V interface between the vehicle underbody wet zone and interior

Contents
48V Two-Way Pass-Through Header

Sealed 48V pass-through interface

The 48V two-way pass-through header creates a sealed connection between the vehicle underbody wet zone and the interior. It supports two sealed eyelet connectors and uses a four-point mounting concept with an integrated harness fixation point. The compact design is intended for mechanical durability, environmental sealing and simpler vehicle integration.

Exploded illustration of the two-way pass-through header, clamp and two eyelet connection points

Electrical performance and environmental resistance

The Lear 48V pass-through header uses bolted electrical connections and supports 70 mm² sealed eyelet connectors for high-current power transmission between vehicle zones. The assembly operates across a temperature range of -40°C to +120°C and meets the USCAR-2 V2 vibration class. Its sealing system is designed to withstand an 80-bar high-pressure water-jet sealing test.

Aluminum-alloy conductive components combine electrical conductivity with reduced weight. The housing and retaining clamp are manufactured from PA66 GF30, while a VMQ silicone foam seal provides environmental protection at the vehicle interface. An integrated third-hand feature helps hold components in position during installation.

Key technical features and benefits:

  • 48 V voltage class
  • Bolted high-current electrical connection
  • Compatible with two sealed 70 mm² eyelet connectors
  • Operating temperature range from -40°C to +120°C
  • USCAR-2 V2 vibration class
  • Designed to withstand an 80-bar high-pressure water-jet sealing test
  • Aluminum-alloy conductive components
  • PA66 GF30 housing and retaining clamp
  • VMQ silicone foam interface seal
  • Third-hand feature for easier positioning during assembly
  • Lightweight material combination for automotive installation
  • Designed for reliable operation between wet and dry vehicle zones

Technical details

  • Voltage class: 48V
  • Sealing class: JLR spec. (80bars HWJS)
  • Vibration class: USCAR2 V2
  • Working temperature: -40°C to 120°C
  • Conductive components: aluminum alloy
  • Plastic body and clamp: PA66 GF30
  • Foam sealing: VMQ (foam silicone)

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