The E1 decarboxylase component of the human branched-chain ketoacid dehydrogenase complex comprises two E1␣ (45.5 kDa) and two E1 (37.5 kDa) subunits forming an ␣ 2  2 tetramer. In patients with type IA maple syrup urine disease, the E1␣ subunit is affected, resulting in the loss of E1 and branched-chain ketoacid dehydrogenase catalytic activities. To study the effect of human E1␣ missense mutations on E1 subunit assembly, we have developed a pulse-chase labeling protocol based on efficient expression and assembly of human (His) 6 -E1␣ and untagged E1 subunits in Escherichia coli in the presence of overexpressed chaperonins GroEL and GroES. Assembly of the two 35 S-labeled E1 subunits was indicated by their co-extraction with Ni 2؉ -nitrilotriacetic acid resin. The nine E1␣ maple syrup urine disease mutants studied showed aberrant kinetics of assembly with normal E1 in the 2-h chase compared with the wild type and can be classified into four categories of normal (N222S-␣ and R220W-␣), moderately slow (G245R-␣), slow (G204S-␣, A240P-␣, F364C-␣, Y368C-␣, and Y393N-␣), and no (T265R-␣) assembly. Prolonged induction in E. coli grown in the YTGK medium or lowering of induction temperature from 37 to 28°C (in the case of T265R-␣), however, resulted in the production of mutant E1 proteins. Separation of purified E1 proteins by sucrose density gradient centrifugation showed that the wild-type E1 existed entirely as ␣ 2  2 tetramers. In contrast, a subset of E1␣ missense mutations caused the occurrence of exclusive ␣ dimers (Y393N-␣ and F364C-␣) or of both ␣ 2  2 tetramers and lower molecular weight species (Y368C-␣ and T265R-␣). Thermal denaturation at 50°C indicated that mutant E1 proteins aggregated more rapidly than wild type (rate constant, 0.19 min ؊1 ), with the T265R-␣ mutant E1 most severely affected (rate constant, 4.45 min ؊1 ). The results establish that the human E1␣ mutations in the putative thiamine pyrophosphate-binding pocket that are studied, with the exception of G204S-␣, have no effect on E1 subunit assembly. The T265R-␣ mutation adversely impacts both E1␣ folding and subunit interactions. The mutations involving the C-terminal aromatic residues impede both the kinetics of subunit assembly and the formation of the native ␣ 2  2 structure.The mammalian mitochondrial branched-chain ␣-ketoacid dehydrogenase (BCKD) 1 complex catalyzes the oxidative decarboxylation of the branched-chain ␣-ketoacids derived from the branched-chain amino acids, leucine, isoleucine, and valine (1). This multienzyme complex is organized around a dihydrolipoyl transacylase (E2) core, to which a branched-chained ␣-ketoacid decarboxylase (E1), a dihydrolipoamide dehydrogenase (E3), a specific kinase, and a specific phosphatase are attached through ionic interactions (2, 3). E1 is a thiamine pyrophosphate (TPP)-dependent enzyme comprising two E1␣ and two E1 subunits that assemble into an ␣ 2  2 tetramer. E2 is a 24-meric protein consisting of identical lipoic acid-bearing subunits arranged on octahedral 4,3,2-point group...