David Clark H8542 Headset Parts Guide & Illustrated Catalog

David Clark H8542 Headset Parts Guide & Illustrated Catalog

Written by: Pilots HQ Staff

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Time to read 7 min

Keep your H8542 flying strong with our complete breakdown of features, parts, and upgrade options.

The **David Clark H8542** is a surround-the-ear pro audio headset designed for professional environments where clear communication is critical. Its defining feature is the M-2H dynamic microphone, which offers excellent noise-cancelling capabilities, making it ideal for high-noise settings such as cockpits and control rooms. This headset ensures that your voice is heard clearly, even in the most demanding conditions.


With a robust build and high-quality components, the H8542 is engineered for durability and reliability. The headset features a 60 Ohm earphone assembly, providing superior audio clarity and fidelity. This makes it an excellent choice for pilots and audio professionals who require precise sound reproduction. Additionally, the headset's XLR connection ensures compatibility with a wide range of audio equipment.


This guide covers everything you need to know about the H8542, from its specifications and noise attenuation features to maintenance tips and part replacements. Whether you're looking to upgrade your headset or perform routine maintenance, this comprehensive breakdown will help you keep your H8542 in peak condition.

The H8542 is a surround-the-ear pro audio headset with a boom mic and XLR connection.

Features the M-2H dynamic microphone, ideal for high-noise environments.

Uses a 60 Ohm earphone assembly for clear audio reproduction.

Compatible with a range of David Clark parts for easy maintenance.

Includes a comm cord kit and overhead cord for versatile connectivity.

Every part number is verified against the official David Clark IPC and Pilots HQ catalog.

Why Pilots Love the David Clark H8542

  • The **M-2H dynamic microphone** provides superior noise cancellation, crucial for clear communication in noisy environments.
  • Robust surround-the-ear design ensures comfort and effective noise isolation, even during extended use.
  • 60 Ohm earphone assembly delivers clear and precise audio, enhancing communication clarity.
  • Compatible with a variety of David Clark parts, making maintenance straightforward and cost-effective.
  • Includes a comm cord kit and overhead cord, offering versatile connectivity options for different setups.
  • Durable construction designed to withstand the rigors of professional use, ensuring long-term reliability.
  • Easy to upgrade with comfort gel ear seals and double-foam head pads for enhanced comfort.
  • Supported by a comprehensive parts catalog, simplifying repairs and replacements.

Specs at a Glance

  • Model Number: H8542
  • Part Number: 19524P-66
  • Microphone: M-2H Dynamic Microphone
  • Earphone Assembly: 60 Ohm
  • Design: Surround-the-Ear

Noise Attenuation


The David Clark H8542 achieves its noise attenuation through a combination of its surround-the-ear design and the use of high-quality ear seals. The headset's geometry creates a tight seal around the ears, effectively blocking out external noise. This passive noise reduction is further enhanced by the M-2H dynamic microphone, which actively cancels ambient noise during transmission.


Over time, the effectiveness of noise attenuation can degrade due to **wear and tear on the ear seals**. Compressed or cracked seals can compromise the acoustic seal, leading to increased noise levels. To maintain optimal performance, it's recommended to replace the ear seals regularly. The Undercut Gel Earseal (pair, part number 40863G-02) is a popular replacement option that enhances comfort and noise isolation.

What's the difference between the David Clark H8542 and H8532?

The David Clark H8542 and H8532 are both part of the pro audio headset lineup, but they cater to slightly different needs. The H8542 is designed with a surround-the-ear configuration, providing more comprehensive noise isolation and comfort for extended wear. In contrast, the H8532 features a more compact design, suitable for environments where space and weight are considerations.


Both models share the same M-2H dynamic microphone, ensuring excellent noise cancellation and clear communication. However, the H8542's design offers a more immersive audio experience, making it ideal for high-noise environments where audio clarity is paramount.


Parts Compatibility

  • Earphone Assembly: Both models use the 60 Ohm earphone assembly, ensuring consistent audio quality.
  • Microphone: The M-2H dynamic microphone is standard across both models, providing reliable noise cancellation.
  • Comm Cord Kit: Compatible with the same comm cord kits, allowing for flexible connectivity options.

If you prioritize comprehensive noise isolation and comfort, the H8542 is the better choice. For a lighter, more compact option, consider the H8532.

Illustrated Parts Catalog

David Clark H8542 Parts Diagram
David Clark

David Clark H8542 Parts List

  1. Adjustable Strap — 10370G-03
  2. Spring Assembly — 10117G-97
  3. Dome, Right — 15522P-03
  4. Dome, Left (mic. side) — 15522P-02
  5. Overhead Cord — 18741G-10
  6. Nut and Washer Kit (10 pk) — 12052G-02
  7. Filter — 11410P-02
  8. Earphone Assembly — 10376G-89
  9. Screws (10 pk) — 00023M-09
  10. Filter — 25629P-05
  11. Filter (1 each) — 14096P-09
  12. Undercut Gel Earseal (pair) — 40863G-02
  13. Dome Filter (1 each) — 15545P-01
  14. Comm Cord Kit — 40599G-08
  15. Boom Attachment Kit — 12840G-19
  16. Mic Boom Assembly — 18740G-34
  17. Microphone M-2H (150 OHM) — 09168P-76
  18. Mic Protector — 40062G-06

H8542 Item # 1 - 12

H8542 Item # 13 - 24

Electrical Schematic

David Clark H8542 Electrical Schematic

Comfort Upgrades Worth Considering for Your David Clark H8542

Looking to make your David Clark H8542 even more comfortable? These two upgrades are customer favorites:

Double-Foam Head Pad Kit (40688G-36):


The double-foam head pad kit offers enhanced cushioning, reducing pressure on the head during long flights. It's an easy upgrade that significantly improves comfort without altering the headset's fit or function.


👉 Ideal for pilots who spend extended hours in the cockpit.

Comfort-Gel Undercut Ear Seals (40863G-02):


These gel ear seals conform to the shape of your ears, providing a better seal and improved noise isolation. They are particularly beneficial for reducing fatigue during long flights.


👉 A must-have for enhancing the overall comfort of your headset.

Maintenance Tips for Your David Clark H8542

  • Regularly inspect the **ear seals** for wear and replace them with part number 40863G-02 as needed to maintain noise isolation.
  • Check the **overhead cord** (part number 18741G-10) for any signs of damage or wear, and replace if necessary to ensure reliable connectivity.
  • Clean the microphone protector (part number 40062G-06) regularly to prevent dust accumulation, which can affect audio quality.
  • Ensure the comm cord kit (part number 40599G-08) is securely connected and free from damage to avoid communication issues.
  • Store the headset in a protective case when not in use to prevent accidental damage and prolong its lifespan.

Keeping your H8542 well-maintained ensures it remains reliable and comfortable for every flight.

Adapters for the David Clark H8542


Enhance the versatility of your **David Clark H8542** with these adapter options:

Accessories for the David Clark H8542

Complete your **David Clark H8542** setup with these essential accessories:

Genuine David Clark Parts, Fast Shipping

At Pilots HQ, we believe our job isn't finished when you buy a headset. We go further by offering:

  • Expert Education: Guides, blogs, and resources that explain how to care for and get the most from your David Clark H8542, including maintenance tips and parts breakdowns.
  • Maintenance Reminders: Helpful tips on when to replace ear seals, cords, and head pads to keep your H8542 comfortable, reliable, and ready for every flight.
  • Trusted Inventory: Only genuine David Clark headsets, adapters, and replacement parts — no imitations.
  • Fast, Reliable Shipping: Get what you need quickly, so your flying isn't delayed by missing parts.
  • Pilot-Focused Service: Our team understands aviation and is here to help you choose the right headset, adapter, or replacement component for your aircraft and mission.

👉 With Pilots HQ, you're not just buying products — you're investing in long-term comfort, clear communication, and confidence every time you fly.

David Clark Company Logo
David Clark Company

How do I replace the ear seals on my H8542?

To replace the ear seals, remove the old seals and attach the new Undercut Gel Earseal (part number 40863G-02) by pressing them firmly into place.

What should I do if the microphone is not picking up my voice clearly?

Check the mic protector (part number 40062G-06) for obstructions and clean it. If the issue persists, inspect the mic boom assembly (part number 18740G-34).

Can I use the H8542 with other audio equipment?

Yes, the H8542's XLR connection allows it to be used with a variety of professional audio equipment.

How often should I replace the overhead cord?

Inspect the overhead cord (part number 18741G-10) regularly for wear and replace it if you notice any damage to maintain optimal performance.

What is the best way to clean the headset?

Use a soft, damp cloth to wipe down the headset. Avoid using harsh chemicals that could damage the components.

What should I do if the headset audio is only coming through one ear?

Check the earphone assembly (part number 10376G-89) for connectivity issues and ensure the comm cord kit (part number 40599G-08) is properly connected.

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Pilots HQ LLC.

Pilots HQ Staff

At Pilots HQ, we’re more than just a store — we’re a crew of aviation enthusiasts and support staff dedicated to helping pilots and professionals get the gear and service they need. Our team shares insights, tips, and stories to keep you flying with confidence.