Ted, So if we don't have the phone setup in the car we need to fabricate a connector? Are explicit instructions included with the unit? I havn't looked what I have yet, but it will either be going in a 01 E53, an 02 E39, or a 03 E39Msport. All 3 just have the Mid, no nav screens. Thanks

Dave,

Not necessarily! Most US spec BMWs of this era came pre-wired for the phone from the factory, so you'll have either the DB25 (large, black, printer cable looking connector), the 26 pin SES, or the 54 pin black connector.

If your car is not pre-wired for the phone, you should really consider an aftermarket mic (which is still plug and play, minus the wire routing), otherwise you're going to have to rip the interior apart to wire in 6 signal wires from the BlueBus to the radio and microphone, and that's just not worth it.

Thanks!
-Ted

Hey Ted. Any comment on the adapter cable to go from the 54 pin black harness to the back of your new unit, for easy connectivity?
Thanks.

Sent from my Pixel 3 using Tapatalk

Sorry for the delay on this front -- I'm working on figuring out exactly what I need to charge.

I'm looking to buy the $5,000 Machine from TE connectivity in order to place the terminals on the wires.

The thought of crimping ~6,000 terminals onto wires by hand is a bit daunting when it takes about 30 seconds per crimp (due to fumbling with the terminal and wire).

Good thing is that I have everything worked out in terms of the cables themselves and more or less what they will cost me to manufacture. I'm trying to get something sent out to everyone before the end of the year.

Thanks!
-Ted

Can the terminal be soldered vs crimped? A jig that holds say 20 you cab maybe get the per unit time down to 5-10 seconds.

Sadly not. I'm using these terminals (all the compatible ones are similar) https://www.mouser.com/ProductDetail/571-878091-CT

If not crimped, they won't install into the housing :/

You need the help of this lady - check out her crimping skills on this video at 03:11 :yikes:

https://www.youtube.com/watch?v=X8CRitTyrsM

That is amazing!

Blew me away... there's a ton of videos like this on industrial processes that just leave you with your mouth hanging open... :popcorn:

Hahaha, wow! She is even crimping the 54 pin connector adapter terminals (they are male terminals)!