The SRM field-joint metal parts, internal case insulation and seals were redesigned and a weather protection system was added.

In the STS 51-L design, the application of actuating pressure to the upstream face of the O-ring was essential for proper joint sealing performance because large sealing gaps were created by pressure-induced deflections, compounded by significantly reduced O-ring sealing performance at low temperature. The major change in the motor case is the new tang capture feature to provide a positive metal-to-metal interference fit around the circumference of the tang and clevis ends of the mating segments. The interference fit limits the deflection between the tang and clevis O-ring sealing surfaces caused by motor pressure and structural loads. The joints are designed so that the seals will not leak under twice the expected structural deflection and rate.

The new design, with the tang capture feature, the interference fit and the use of custom shims between the outer surface of the tang and inner surface of the outer clevis leg, controls the O-ring sealing gap dimension. The sealing gap and the O-ring seals are designed so that a positive compression (squeeze) is always on the O-rings. The minimum and maximum squeeze requirements include the effects of temperature, O-ring resiliency and compression set, and pressure. The clevis O-ring groove dimension has been increased so that the O-ring never fills more than 90 percent of the O-ring groove and pressure actuation is enhanced.

The new field joint design also includes a new O-ring in the capture feature and an additional leak check port to ensure that the primary O-ring is positioned in the proper sealing direction at ignition. This new or third O-ring also serves as a thermal barrier in case the sealed insulation is breached.

The field joint internal case insulation was modified to be sealed with a pressure-actuated flap called a J-seal, rather than with putty as in the STS 51-L configuration.

Longer field-joint-case mating pins, with a reconfigured retainer band, were added to improve the shear strength of the pins and increase the metal parts' joint margin of safety. The joint safety margins, both thermal and structural, are being demonstrated over the full ranges of ambient temperature, storage compression, grease effect, assembly stresses and other environments. External heaters with integral weather seals were incorporated to maintain the joint and O-ring temperature at a minimum of 75º F. The weather seal also prevents water intrusion into the joint.