The final steps in the envelopment of Sindbis virus involve specific interactions of the E2 endodomain with the virus nucleocapsid. Deleting E2 K at position 391 (E2 ⌬K391) resulted in the disruption of virus assembly in mammalian cells but not insect cells (host range mutant). This suggested unique interactions of the E2 ⌬K391 endodomain with the different biochemical environments of the mammalian and insect cell lipid bilayers. To further investigate the role of the amino acid residues located at or around position E2 391 and constraints on the length of the endodomain on virus assembly, amino acid insertions/substitutions at the transmembrane/endodomain junction were constructed. An additional K was inserted at amino acid position 392 (KK391/392), a K3F substitution at position 391 was constructed (F391), and an additional F was inserted at 392 (FF391/392). These changes should lengthen the endodomain in the KK391/392 insertion mutant or shorten the endodomain in the FF391/392 mutant. The mutant FF391/392 grown in BHK cells formed virus particles containing extruded material not found on wild-type virus. This characteristic was not seen in FF391/392 virus grown in insect cells. The mutant KK391/392 grown in BHK cells was defective in the final membrane fission reaction, producing multicored or conjoined virus particles. The production of these aberrant particles was ameliorated when the KK391/392 mutant was grown in insect cells. These data indicate that there is a critical minimal spanning distance from the E2 membrane proximal amino acid at position 391 and the conserved E2 Y400 residue. The observed phenotypes of these mutants also invoke an important role of the specific host membrane lipid composition on virus architecture and infectivity.The alphavirus Sindbis is an excellent model for the study of the assembly of membrane-containing viruses. Unlike the majority of enveloped viruses, which are loosely structured protein modified membrane envelopes, the alphaviruses are highly organized icosahedral protein shells with an associated membrane (17,36,40). The three proteins of Sindbis virus are organized into two nested protein shells with T ϭ 4 icosahedral symmetry (38). The outer protein shell contains 240 copies of glycoproteins E1 and E2. The inner protein shell contains 240 copies of the capsid protein C which are assembled around the plus-sense single-stranded RNA (48). The structure of the virus is stabilized through specific E1-E1 interactions, and anchoring of the outer protein shell to the inner protein shell occurs through specific associations of the E2 glycoproteins with the capsid proteins across the intervening host cell membrane (1, 22, 23). The E2-capsid interactions are acquired in the final stages of virus assembly as the virus capsid is enveloped in the E1-E2 modified plasma membrane (5, 27). These E2-capsid interactions occur for each of the 240 copies of E2 and capsid protein holding the mature virion in a high energy, metastable conformation (2,8,34). Energy stored in the E1 glycoprot...