Humanetics Hybrid III 5th Female User manual

880105-9900 User Manual Hybrid III 5th Female Rev G Page 1 of 86
© 2020 Humanetics Innovative Solutions
Hybrid III 5th Female
User Manual
880105-000-XH

880105-9900 User Manual Hybrid III 5th Female Rev G Page 2 of 86
© 2020 Humanetics Innovative Solutions
For information on Humanetics products, please visit our web site at www.humaneticsatd.com
or contact:
Humanetics Innovative Solutions
23300 Haggerty Road
Farmington Hills, MI 48335, USA
Telephone: [phone]
Fax: [phone]
No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form
or by any means, electronic, photocopying, recording, mechanical or otherwise, without the express
written consent of Humanetics Innovative Solutions.
Copyright © 2020 Humanetics Innovative Solutions. All rights reserved.
The information in this manual is furnished for informational use only and is subject to change without
notice. Humanetics Innovative Solutions assumes no responsibility or liability for any errors or
inaccuracies that may appear in this manual.
Notice: This product may contain lead
A list of components that may contain lead is being maintained on the Humanetics web site. The list,
organized by dummy type, shows subcomponents that may currently or in the past have contained
lead or a lead-based alloy. Please refer to the Humanetics web site under ATD Lead Disclosure for
information regarding lead in this product. http://www.humaneticsatd.com/Lead_Disclosure

880105-9900 User Manual Hybrid III 5th Female Rev G Page 3 of 86
© 2020 Humanetics Innovative Solutions
Table of Contents
Section – 1 Introduction ................................................................................................................................6
1.1 Foreword.................................................................................................................................................6
1.2 Manual Overview ....................................................................................................................................6
1.2.1 Appendices..................................................................................................................................6
1.2.2 SAE Documents..........................................................................................................................6
1.2.3 SAE Test Definitions ...................................................................................................................6
1.2.4 Abbreviations...............................................................................................................................7
1.3 Construction............................................................................................................................................8
1.4 Clothing...................................................................................................................................................8
1.5 Instrumentation .......................................................................................................................................9
1.6 Special Tools.........................................................................................................................................11
Section 2 – Head and Neck Removal.........................................................................................................12
2.1 Disassembly......................................................................................................................................12
2.2 Reassembly......................................................................................................................................14
2.3 Inspection..........................................................................................................................................14
Section 3- Head Assembly..........................................................................................................................15
3.1 Disassembly......................................................................................................................................16
3.2 Reassembly......................................................................................................................................16
3.3 Inspection..........................................................................................................................................16
Section 4 – Neck Assembly ........................................................................................................................18
4.1 Disassembly......................................................................................................................................19
4.2 Reassembly......................................................................................................................................20
4.3 Inspection..........................................................................................................................................20
Section 5 – Upper Torso Assembly ............................................................................................................21
5.1 Disassembly......................................................................................................................................24
5.2 Reassembly......................................................................................................................................25
5.3 Inspection..........................................................................................................................................26
5.4 Chest Deflection Disassembly..........................................................................................................30
5.5 Chest Deflection Reassembly...........................................................................................................30
5.6 Chest Deflection Inspection..............................................................................................................31
5.7 Shoulder Assembly...........................................................................................................................32
5.8 Shoulder Disassembly......................................................................................................................33
5.9 Shoulder Reassembly.......................................................................................................................34
5.10 Shoulder Inspection........................................................................................................................34
Section 6 – Lower Torso Assembly ............................................................................................................35
6.1 Lumbar Disassembly ........................................................................................................................37
6.2 Lumbar Reassembly.........................................................................................................................37
6.3 Pelvis Disassembly...........................................................................................................................38
6.4 Pelvis Reassembly ...........................................................................................................................40
6.5 Lower Torso Inspection ....................................................................................................................40
Section 7- Arm Assembly............................................................................................................................41
7.1 Disassembly......................................................................................................................................42
7.2 Reassembly......................................................................................................................................42
7.3 Inspection..........................................................................................................................................42
Section 8- Leg Assembly ............................................................................................................................43
8.1 Leg Disassembly ..............................................................................................................................44
8.2 Leg Reassembly...............................................................................................................................44
8.3 Leg Inspection ..................................................................................................................................44
8.4 Lower Leg Disassembly....................................................................................................................46
8.5 Lower Leg Reassembly ....................................................................................................................46
8.6 Lower Leg Inspection........................................................................................................................46
8.7 Ankle Disassembly ...........................................................................................................................48
8.8 Ankle Reassembly............................................................................................................................48
8.9 Ankle Inspection ...............................................................................................................................48
8.10 Instrumented Leg Disassembly ......................................................................................................49

880105-9900 User Manual Hybrid III 5th Female Rev G Page 4 of 86
© 2020 Humanetics Innovative Solutions
8.11 Instrumented Leg Reassembly.......................................................................................................50
Section 9– Calibration Tests.......................................................................................................................51
9.1 Head Drop Test ................................................................................................................................51
9.2 Neck Test..........................................................................................................................................53
9.3 Thorax Impact Test...........................................................................................................................58
9.4 Knee Impact Test..............................................................................................................................61
9.5 Knee Slider Test ...............................................................................................................................63
Section 10 – Inspection Tests.....................................................................................................................66
10.1 External Measurement Procedure..................................................................................................66
10.2 Hip Joint Range of Motion ..............................................................................................................70
10.3 Design Reference, Foot Test..........................................................................................................72
10.4 Design Reference, Ankle Motion Test............................................................................................74
10.5 Design Reference, Torso Flexion Test...........................................................................................78
Section 11 – Appendices ............................................................................................................................81
11.1 Appendix A .....................................................................................................................................81
11.1.1 Accelerometer Handling Guidelines........................................................................................81
11.2 Appendix B .....................................................................................................................................83
11.2.1 Guidelines for Repairing Flesh................................................................................................83
11.3 Appendix C .....................................................................................................................................84
11.3.1 Joint Adjustment Procedures ..................................................................................................84
11.4 Appendix D .....................................................................................................................................85
11.4.1 Axial Integrity of the Neck........................................................................................................85
11.5 Appendix E .....................................................................................................................................85

880105-9900 User Manual Hybrid III 5th Female Rev G Page 5 of 86
© 2020 Humanetics Innovative Solutions
List of Figures
Figure 1.1 – Accelerometer Location in Dummy.........................................................................................10
Figure 2.1- Disassembling the Head and Neck ..........................................................................................12
Figure 2.2 – Neck Compression Tool .........................................................................................................13
Figure 2.3 – Neck Removal.........................................................................................................................13
Figure 3.1 – Head Assembly.......................................................................................................................15
Figure 4.1 – Neck Assembly.......................................................................................................................18
Figure 4.2 - Nodding Block Orientation.......................................................................................................19
Figure 5.1 – Upper Torso Front View..........................................................................................................21
Figure 5.2 – Upper Torso Front View..........................................................................................................22
Figure 5.3- Upper Torso Side View.............................................................................................................23
Figure 5.4- Chest Depth Gage (880105-811).............................................................................................26
Figure 5.5- Chest Depth Gage (880105-813).............................................................................................27
Figure 5.6- Chest Depth Measurement Setup............................................................................................28
Figure 5.7- Chest Deflection Transducer Assembly ...................................................................................29
Figure 5.9- Shoulder Assembly Exploded View..........................................................................................32
Figure 6.1 – Lower Torso Front View..........................................................................................................35
Figure 6.2- Lower Torso Side View.............................................................................................................36
Figure 6.3 – Lower Torso Top View............................................................................................................36
Figure 6.4- Lumbar Spine Assembly...........................................................................................................39
Figure 6.5- Pelvic Reference.......................................................................................................................40
Figure 7.1- Arm Assembly Exploded View..................................................................................................41
Figure 8.1- Leg Assembly Exploded View..................................................................................................43
Figure 8.2- Sliding Knee Exploded View.....................................................................................................45
Figure 8.3 – Ankle Assembly Exploded View .............................................................................................47
Figure 8.4- Instrumented Lower Leg...........................................................................................................49
Figure 9.1- Head Drop Test Setup Specifications.......................................................................................53
Figure 9.2 – Neck Pendulum Arm Specifications .......................................................................................56
Figure 9.3 – Neck Extension Test Setup Specifications.............................................................................57
Figure 9.4 – Neck Flexion Test Set-Up Specifications ...............................................................................57
Figure 9.5 -Thorax Impact Test Setup Specifications.................................................................................60
Figure 9.6 – Hystersis Definition.................................................................................................................61
Figure 9.7 – Knee Impact Test Setup Specifications..................................................................................63
Figure 9.8 – Knee Slider Test Setup Specifications ...................................................................................65
Figure 10.1 – External Dimension Measurement........................................................................................68
Figure 10.2- Hip Joint Range of Motion Test Setup....................................................................................72
Figure 10.3 – Compression Test Setup......................................................................................................73
Figure 10.4- Foot Compression Test Performance Specifications.............................................................74
Figure 10.5 – Leg Reference Planes ..........................................................................................................76
Figure 10.6- Ankle/Foot Reference Planes.................................................................................................77
Figure 10.7- Torso Flexion Bracket Assembly............................................................................................79
Figure 10.8 – Torso Flexion Test Setup......................................................................................................80

880105-9900 User Manual Hybrid III 5th Female Rev G Page 6 of 86
© 2020 Humanetics Innovative Solutions
Section – 1 Introduction
1.1 Foreword
In the late 1980’s the Center for Disease Control (CDC) awarded Ohio State University a grant to develop
multi-sized test dummies based on the Hybrid III design. To aid in this endeavor, the Mechanical Human
Simulation Subcommittee of the Society of Automotive Engineers (SAE) formed a Task Group to define
the specifications for an adult size small female dummy which would have, at least, the same level of
biofidelity and measurement capacity as the 50th Hybrid III Dummy.
The Hybrid III Small Female Test Dummy is based on the characteristic size and weight measurements
taken from anthropometry studies of the 5th percentile adult female. Its impact response requirements for
the head, neck, chest, hip, knee and ankle were extrapolated from the biofidelity requirements of the
Hybrid III mid-size male dummy. (see Mertz, H. J., Irwin, A. I., Melvin, J. W., Stalnaker, R. L., Beebe, M.
S., “Size, Weight, and Biomechanical Impact Response Requirements for Adult Size Small Female and
Large Male Dummies”, SAE #890756, SP-782, 1989.) The Hybrid III small female dummy is designed to
represent the lower extreme of the United States adult population.
1.2 Manual Overview
1.2.1 Appendices
Several guidelines and procedures apply to various parts throughout the dummy, and are included in the
appendices for easier reference. First, when handling an instrumented dummy, improper techniques can
damage instrumentation, particularly accelerometers. Appendix A contains guidelines for safe handling of
instrumented dummies. Second, the vinyl flesh of dummies can be damaged, but is often repairable.
Appendix B contains instructions for repairing dummy flesh. Third, procedures for adjusting the joints
throughout the dummy are included in Appendix C.
1.2.2 SAE Documents
In addition to the attached appendices, other SAE publications are particularly useful when working with
the Hybrid III dummies. SAE J211 provides the most recent guidelines and procedures for dummy
instrumentation and filtering. SAE Information Report J1733 illustrates the instrumentation available for the
Hybrid III dummy, along with descriptions of how to apply the positive right-hand rule sign convention.
1.2.3 SAE Test Definitions
Calibration Test:
Calibration tests are specified for dummy responses which could affect dummy measurements that are
used by government and safety engineers to assess occupant injury potential. Calibration tests are
performed by the dummy manufacturer to assure that a new component or assembly meets the SAE
specified response requirements. The crash dummy user will periodically perform the calibration tests to
assure the dummy is maintained at the SAE specified performance levels.
Inspection Test:
Inspection tests are supplemental to the calibration tests to insure that a component meets its design
intent. They are performed by the dummy manufacturer on new parts. The dummy user may conduct
inspection tests when a part is damaged or replaced.

880105-9900 User Manual Hybrid III 5th Female Rev G Page 7 of 86
© 2020 Humanetics Innovative Solutions
1.2.4 Abbreviations
The following threaded fastener abbreviations are used in this manual.
SHCS………………………….Socket Head Cap Screw
FHCS………………………….Flat Head Cap Screw
BHCS………………………….Button Head Cap Screw
SHSS………………………….Socket Head Shoulder Screw
SSCP………………………….Socket Screw, Cup Point
RHMS…………………………Round Head Machine Screw

880105-9900 User Manual Hybrid III 5th Female Rev G Page 8 of 86
© 2020 Humanetics Innovative Solutions
1.3 Construction
The skull and skull cap are both one-piece cast aluminum, with a removable one-piece vinyl head and
skull cap skin. The skull cap is removable for access to the head instrumentation. The vinyl skin is
tuned to give human-like response to forehead impacts.
The neck has a biofidelic “angle versus moment” response in both dynamic flexion (forward bending)
and extension (rearward bending) articulations.
A neck cable controls stretching responses, and increases the neck’s durability to high axial tension
forces.
The two-piece aluminum clavicle and clavicle-link assembly have cast integral scapulae to prevent
interface with shoulder belts.
Six spring steel ribs with polymer-based damping material approximate the human chest force-
deflection response characteristics. The sternum assembly connects to the front of the ribs and
incorporates a slider for a chest deflection transducer to measure rib cage deflection relative to the
thoracic spine.
A straight lumbar spine gives a sitting posture to simulate a person of larger stature in the driving
position.
The pelvis has a human shape and comes equipped with load cell replacements for pelvis
submarining-indicating transducers.
A knee slider mechanism is used that consists of steel sliders with energy absorbing molded rubber
mounted on aluminum knees. This allows for displacement of the tibia relative to the femur, simulating
ligament response.
The leg assemblies are steel tubes covered with vinyl. The legs are interchangeable with instrumented
versions.
Constant friction movable joints are used that need few adjustments and provide consistent
articulations.
The standard model has a "seated" pelvis construction. A “sit/stand" pelvis version is optional as are a
neck covering for airbag testing, a deformable face for steering wheel rim testing, and a deformable
abdomen for lap belt submarining and steering wheel rim evaluations.
1.4 Clothing
When used in testing, the dummy should wear snug-fitting cotton knit T-shirt and pants. The neckline
should be small enough to prevent contact between a shoulder belt and the dummy’s skin. The pants
should end above the dummy’s knee. The T-shirt and pants should each weigh no more than 0.14 kg (0.3
lb). Garments similar to thermal underwear (trimmed to be short-sleeved and above the knee) usually meet
these requirements. To improve the quality of high-speed films taken of the dummy during testing (by
avoiding excessive glare); the garments are usually dyed to a light pink. The shoes used with the small
adult female dummy are women’s low dress black oxfords; size 7-1/2 E that meet military specification
MIL-S-21711E. Each shoe weighs 0.41 ± 0.09 kg (.9 ± 0.2 lb). To make it easier to put the shoe on the
dummy, the shoe should be cut to extend the tongue. Talc may also be applied to the foot.

880105-9900 User Manual Hybrid III 5th Female Rev G Page 9 of 86
© 2020 Humanetics Innovative Solutions
1.5 Instrumentation
When ordering a new dummy, inform the dummy manufacturer of the type and model of accelerometer
you intend to use. This will ensure that you obtain the correct accelerometer mounts for the head, chest
and pelvis.
The following is an instrumentation list currently available for the Hybrid III 5th Female dummy.
Instrument Part Number Number of
Channels Quantity
Head Accelerometers IE-103 3 3
Upper Neck Load Cell
IF-205
6
1
IF-205J 6 1
IF-207
6
1
IF-256 4 1
IF-2564
3
1
Lower Neck Load Cell IF-211 5 1
IF-228
6
1
IF-238 6 1
Chest Accelerometers
IE-103
3
3
Sternum Accelerometers IE-103 3 3
Spine Accelerometers
IE-103
3
3
Chest Deflection: Rotary Pot 78051-342 1 1
Thoracic Spine Load Cell
IF-300
6
1
IF-302 5 1
Clavicle Load Cell
IF-353
2
1
Lumbar Spine Load Cell IF-404 5 1
IF-406
6
1
IF-429 3 1
Rib Load Cell
IF-455
4
1
Pelvis Accelerometers IE-103 3 3
ASIS Load Cells
IF-509
2
1
Femur Load Cells IF-604 2 2
IF-625
6
2
IF-628 6 2
Knee Clevis Load Cells
IF-805
2
2
Knee Sheer Displacement 880105-516 1 2
Upper Tibia Load Cells
IF-820
8
2
IF-857 5 2
Lower Tibia Load Cells
IF-819
8
2
IF-825 8 2
IF-853
5
2
Table 1.1 – Instrumentation
* The load cell part numbers listed in the table are for 350 ohm’s. 120 ohm’s load cells are also available.

880105-9900 User Manual Hybrid III 5th Female Rev G Page 10 of 86
© 2020 Humanetics Innovative Solutions
Figure 1.1 – Accelerometer Location in Dummy
ITEM
QTY
PART NO.
DESCRIPTION
1
15
IE-103
ACCELEROMETER ENDEVCO/ENTRAN 7264-2000 (REF)
2
3
H350-1005
TRIAXIAL MOUNTING BLOCK
3
1
880105-1211
HEAD ACCELEROMETER MOUNT
4
4
9000487
SCREW, SHCS #10-24 X 3/8
5
18
9000152
SCREW, SHCS #0-80 X 1/8 (REF)
6
6
9000531
SCREW, SHCS #2-56 X 5/8
7
1
H350-1006
CHEST ACCELEROMETER MOUNT
8 1
880105-1220
PELVIC ACCELEROMETER MOUNT (OPTIONAL)
1200056
PELVIC ACCELEROMETER MOUNT
9
1
9000490
SCREW, SHCS 3/8-16 X 3/4
10
4
9000624
SCREW, SHCS #10-24 X 1/2
Table 1.2- Accelerometer Location Parts List

880105-9900 User Manual Hybrid III 5th Female Rev G Page 11 of 86
© 2020 Humanetics Innovative Solutions
1.6 Special Tools
The following special tools will allow assembly, disassembly and calibration of the Hybrid III 95th Male
dummy. For information concerning tool availability, contact the dummy manufacturers.
Neck compression tool
Ball hex wrench set
Lumbar cable nut wrench
Pelvis angle measurement tool
Chest depth gauge

880105-9900 User Manual Hybrid III 5th Female Rev G Page 12 of 86
© 2020 Humanetics Innovative Solutions
Section 2 – Head and Neck Removal
2.1 Disassembly
To disassemble the head and neck, detach the head-neck assembly from the upper torso. This is done by
removing the 3/8-16 x 1 SHCS Nylok® (Item 1, Figure 2.1) and clamping washer (Item 2) that hold the
upper neck bracket to the lower neck bracket.
Notice that the clamping washer is curved on one side. This curvature is designed to mate with the radius
on the underside of the lower neck bracket; be sure to install this properly during reassembly. With this
screw removed, remove the hex jam nut (Item 3), flat washer (Item 4), and four 10-24 x 5/8 SHCS (Item 5)
that hold the upper neck bracket to the sternum bib and neck assembly. Remove the neck from the
sternum bib.
To disassemble the head assembly from the neck, remove the four 10-24 x 1/2 SHCS (Item 6) that hold
the skull cap in place. Completing the removal of the head from the neck will require the use of a
compression tool to squeeze the nodding blocks (Item 7) located between the head and neck. If the
nodding blocks are not compressed, it will be difficult and possibly damaging to remove the neck pivot pin
(Item 12, Figure 3.1). When disassembling the head, the load cell can remain in the head. Loosen the two
set screws (Item 11, Figure 3.1) that hold the pivot pin.
Figure 2.1- Disassembling the Head and Neck

880105-9900 User Manual Hybrid III 5th Female Rev G Page 13 of 86
© 2020 Humanetics Innovative Solutions
Figure 2.2 – Neck Compression Tool
Remove the skull cap and attach the H3-5 adapter to the back of the head using at least two 10-24 x 3/8
SHCS . Then place the exposed portion of the neck cable in the cylindrical cup on the tool, and attach the
compression tool to the adapter plate as shown in Figure 2.3 with at least two 1/4-20 x 1-3/8 SHCS. With
the tool attached, turn the handle until the nodding blocks are compressed enough to relieve the pressure
on the pin. The pivot pin should slide out of the load cell or load cell replacement easily, but may require a
light tap with a rubber mallet.
Figure 2.3 – Neck Removal
After the pin is removed, detach the tool. The neck will then be free to be pulled away from the head
assembly. There are two brass washers located inside of the pivot pin joint that will fall out as the two
components are separated. Do not confuse the brass washers with any others; they are trimmed for the
proper fit of this joint.

880105-9900 User Manual Hybrid III 5th Female Rev G Page 14 of 86
© 2020 Humanetics Innovative Solutions
Note: Newly purchased washers (78051-253) should be trimmed using the following procedure:
Trimming can be accomplished in several ways. The easiest is to rub the washer on coarse
sandpaper or a file and check and recheck the fit of the joint. Repeat the trimming until the
nodding joint and the load cell can be assembled snugly with the washers.
The fit of the nodding joint and load cell should be snug but easily assembled.
2.2 Reassembly
Reattach the neck to the head.
Reattach the skull cap to the back of the head.
Reattach the neck and the upper neck bracket to the sternum bib.
Position the upper neck bracket so it is positioned at the zero degree mark on the neck bracket.
Reattach the upper neck bracket to the lower neck bracket.
2.3 Inspection
Check for tears or breaks in the neck.

880105-9900 User Manual Hybrid III 5th Female Rev G Page 15 of 86
© 2020 Humanetics Innovative Solutions
Section 3- Head Assembly
Figure 3.1 is an exploded view of the Head Assembly. Table 3.1 gives a general description of each item.
Figure 3.1 – Head Assembly
ITEM
QTY
PART NO.
DESCRIPTION
1
1
78051-383X
STRUCT. REPLACEMENT 6-AXIS NECK TRANS.
2
1
880105-1211
HEAD ACCEL. MOUNT 7264-2000 (REF)
3
1
880105-102
SKULL , 6-AXIS NECK
4
1
880105-103
SKULL CAP
5
1
880105-109
SKIN, HEAD
6
1
880105-106
SKIN, SKULL CAP
7
4
9000264
SCREW, SHCS ¼-28 X 7/8
8
4
9000624
SCREW, SHCS 10-24 X 1/2
9
4
9000677
WASHER, ¼ ID X 3/8 OD X 1/16
10
4
9000487
SCREW, SHCS #10-24 X 3/8 (REF)
11
2
9000452
SCREW, SSCP #8-32 X 1/4
12
1
780951-339
PIVOT PIN, NECK TRANDUCER
Table 3.1 - Head Assembly (880105-100X) Part List

880105-9900 User Manual Hybrid III 5th Female Rev G Page 16 of 86
© 2020 Humanetics Innovative Solutions
3.1 Disassembly
When the neck is detached from the head, the remaining components can be disassembled from the head
assembly. Remove the four 1/4-28 x 7/8 SHCS (Item 7, Figure 3.1) from the six-channel load cell or
structural replacement. To remove the six-channel neck load cell or structural replacement from
the assembly, it is necessary to pull the load cell out from the inside of the head through the back of the
head.
The head skin can be pulled off of the head assembly by lifting the skin away from the skull at the back of
the skull and “peeling” the flesh from the assembly. The head skin recommended for use by SAE is shown
in Side view of head skin with filled chin (Figure 3.2 and 3.3). This version’s design is intended to keep
deploying airbags from getting between the back surface of the jaw flesh and the front surface
of the neck.
3.2 Reassembly
Put the head skin back on the skull, paying close attention to the fit of the flesh around the skull,
particularly in the forehead area.
Reattach the six-channel load cell or structural replacement.
3.3 Inspection
Check the head skin for cracks or tears. Repair the head skin as indicated in Appendix B. Do not
repair damage in the forehead region as this will affect test results; instead, replace the head skin.
If the head skin does not feel soft and pliable, re-certify or replace the head skin.
Check the skull for cracks or dents. Replace the skull if structurally damaged in any way.
Figure 3.2 – Side view of head skin with filled chin

880105-9900 User Manual Hybrid III 5th Female Rev G Page 17 of 86
© 2020 Humanetics Innovative Solutions
Figure 3.3 – Bottom of head skin with filled chin

880105-9900 User Manual Hybrid III 5th Female Rev G Page 18 of 86
© 2020 Humanetics Innovative Solutions
Section 4 – Neck Assembly
Figure 4.1 is an exploded view of the Neck Assembly. Table 4.1 gives a general description of each item.
Figure 4.1 – Neck Assembly

880105-9900 User Manual Hybrid III 5th Female Rev G Page 19 of 86
© 2020 Humanetics Innovative Solutions
ITEM
QTY
PART NO.
DESCRIPTION
1
4
9000566
SCREW, FHCS #10-24 x 5/8
2
2
78051-351
NODDING BLOCK
3
1
880105-201
NODDING JOINT NECK ASSEMBLY
4
1
180-2004
BUSHING UPPER
5
1
880105-255
NECK MOLDED-TESTED & CERT.
6
1
880105-206
NECK CABLE
7
1
180-2005
BUSHING LOWER
8
4
9000244
SCREW, SHCS #10-24 X 5/8
9
1
9000018
NUT, HEX JAM ½-20
10
1
9001260
WASHER, 1.06 OD X .53 ID X .06
11
1
880105-207
UPPER NECK BRACKET
12
1
880105-1060
BIB ASSEMBLY (REF) (NOT SHOWN)
13
2
78051-253
WASHER, NODDING JOINT
14
1
9000710
WASHER FLAT 7/32 ID X 3/8 OD X 1/32
Table 4.1 – Neck Assembly (880105-250) Part List
Once separated, check the condition of the two rubber neck nodding blocks on the top of the nodding joint.
The 90°surfaces of the nodding blocks fit opposite, rather than inside, the 90°grooves of the head-to-neck
adaptor bracket (Figure 4.2).
Figure 4.2 - Nodding Block Orientation
4.1 Disassembly
To disassemble the neck assembly, remove the four 10-24 x 5/8 FHCS (Item 1, Figure 4.1) from the top of
the nodding joint. With the joint removed, the neck cable (Item 6, Figure 4.1) can be pulled out of the neck.
Remove the cable bushings (Items 4 and 7, Figure 4.1) from each end of the cable.

880105-9900 User Manual Hybrid III 5th Female Rev G Page 20 of 86
© 2020 Humanetics Innovative Solutions
4.2 Reassembly
The upper end of the neck is machined to accept the cable ball end bushing of the neck cable.
During reassembly, make sure that this area is free of any extraneous rubber material before
installing the cable. Put the cable bushings on each end of the cable. The neck cable (Item 6,
Figure 4.1) must be inserted in the neck with the “ball” end seated in the cup at the upper end of
the neck.
The torque on the Hex Jam Nut (Item 9, Figure 4.1) should be 1.4 ± 0.2 N·m (12 ± 2 in·lbf).
Install the nodding joint to the neck using the four screws (Item 1, Figure 4.1).
The SAE has recommended that a single layer of 6.3 mm (0.25 inch) thick by 244 mm (9.6 inch)
long by 127 mm (5.0 inch) high neoprene closed-cell rubber foam be wrapped around the neck
and secured with Velcro® (or equivalent) at the bottom in the rear. The Velcro® loop is 19 mm
(0.75 inch) wide and 64 mm (2.5 inch) long. This neck shield is intended to prevent the airbag from
getting into the slits in the rubber neck discs.
4.3 Inspection
Check for tears or breaks in the neck.
Check the nodding blocks for wear and deformation. Noise and improper loading of the nodding
joint will occur with damaged blocks.
Check the hardness of the nodding blocks often with a shore “A” type durometer. The specification
is 80-90
Check the axial integrity of the neck. (see Appendix D)
The neck cable should be torqued to 1.4 ± 0.2 N·m (12.0 ± 2 in·lbf). Check the neck cable by
observing the strands. If they are not tightly wound, or the cable seems larger in diameter on one
end, replace the cable. If the cable cannot be properly torqued, replace the cable.