Methods and apparatus are provided for manufacturing a portable electronic device that does not cause yield loss or premature failure due a connector shell contacting the housing or its attached components during assembly. One example provides a connector shell that is split in at least two separate pieces or portions. A first piece of the connector shell is attached to a subassembly. A second piece of the connector shell is attached to or included as part of an endcap. During assembly, the subassembly and first connector shell piece is inserted into a housing from a first end. The endcap and the second piece of the connector shell can then be inserted into, or attached to, a second end of the housing.