David Clark H8592 Headset Parts Guide & Illustrated Catalog

David Clark H8592 Headset Parts Guide & Illustrated Catalog

Written by: Pilots HQ Staff

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Time to read 7 min

Keep your H8592 flying strong with our complete breakdown of features, parts, and upgrade options.

The David Clark H8592 is a single-ear pro audio headset designed for professionals who demand clarity and comfort. Its defining feature is the M-2H dynamic microphone, which provides superior noise cancellation, ensuring clear communication even in high-noise environments. This makes the H8592 an excellent choice for audio professionals who need reliable performance in demanding conditions.


With its lightweight design, the H8592 is comfortable for extended wear, making it ideal for long work sessions. The headset's components, such as the headband and ear seals, are designed for durability and ease of replacement, ensuring that the headset remains in top condition over time. This focus on comfort and longevity makes the H8592 a preferred choice among professionals.


This guide will cover everything you need to know about the H8592, from its technical specifications to maintenance tips and available upgrades. Whether you're looking to replace a worn-out part or enhance your headset's performance, this comprehensive breakdown will provide the insights you need to keep your H8592 performing at its best.

The H8592 is a single-ear pro audio headset with a noise-canceling microphone.

It features a lightweight design, ideal for long-duration use in professional audio settings.

The M-2H dynamic microphone ensures clear communication in noisy environments.

Compatible with a variety of communication systems, thanks to its versatile comm cord kit.

The headset's parts are easily replaceable, ensuring long-term usability and performance.

Why Pilots Love the David Clark H8592

  • Single-ear design allows for ambient sound awareness, crucial for professional audio applications.
  • The M-2H dynamic microphone ensures clear communication with its 150 Ohm impedance, ideal for noisy environments.
  • Lightweight construction reduces fatigue during extended use, enhancing comfort for long sessions.
  • Compatible with a wide range of communication systems, thanks to the versatile Comm Cord Kit (40599G-08).
  • Durable components like the Headband Spring (15093P-03) ensure long-lasting performance.
  • Easy-to-replace parts, such as the Undercut Gel Earseal (40863G-02), simplify maintenance and extend headset life.
  • The headset's modular design allows for quick customization and upgrades, meeting diverse professional needs.
  • Every part number in this guide is sourced directly from the official David Clark IPC and cross-referenced against the Pilots HQ catalog.

Specs at a Glance

  • Model Number: H8592
  • Part Number: 40722G-01
  • Microphone: M-2H Dynamic, 150 Ohm
  • Design: Single-ear, Over-the-head

Noise Attenuation


The David Clark H8592 headset provides effective noise attenuation through its single-ear design, which is complemented by the M-2H dynamic microphone. This microphone is specifically engineered to cancel out ambient noise, ensuring that your voice is transmitted clearly even in high-noise environments. The headset's ear seal, part number 40863G-02, plays a crucial role in isolating sound, enhancing both comfort and audio clarity.


Over time, the effectiveness of the noise attenuation can degrade, primarily due to wear and tear on the ear seals. Compressed or damaged seals can compromise the acoustic seal, leading to increased ambient noise intrusion. Regular replacement of the ear seals is recommended to maintain optimal performance. The Undercut Gel Earseal, listed as item 1 in the IPC, is a cost-effective replacement that restores the headset's original noise-canceling capabilities.

What's the difference between the David Clark H8592 and H8590?

The David Clark H8592 and H8590 are both single-ear pro audio headsets, but they cater to slightly different needs. The H8592 is equipped with the M-2H dynamic microphone, which offers superior noise cancellation, making it ideal for environments with high ambient noise. In contrast, the H8590 features a different microphone configuration that may be more suited to quieter settings.


Both models share a similar lightweight design, ensuring comfort during long sessions. However, the H8592's enhanced noise-canceling capabilities make it a preferred choice for professionals who require clear communication in challenging audio environments.


Parts Compatibility

  • Microphone: The M-2H dynamic microphone (09168P-76) is unique to the H8592.
  • Ear Seals: Both models use the same Undercut Gel Earseal (40863G-02), ensuring easy replacement and maintenance.
  • Comm Cord Kit: The H8592 uses the Comm Cord Kit (40599G-08), which is not compatible with the H8590.

👉 For professionals needing robust noise cancellation, the H8592 is the better choice, while the H8590 may suffice for quieter environments.

Illustrated Parts Catalog

David Clark H8592 Parts Diagram
David Clark

David Clark H8592 Parts List

  1. Undercut Gel Earseal (pair) — 40863G-02
  2. Filter (1 each) — 14096P-09
  3. Dome Filter (1 each) — 25629P-03
  4. Screw/Grommet Kit (4 pk) — 18900G-47
  5. Earphone Assembly — 10376G-89
  6. Headpad Restraint, Foam — 40266G-01
  7. Temple Pad Assy Kit — 18900G-37
  8. Headpad Assembly — 18900G-45
  9. Headband Spring — 15093P-03
  10. Filter (1 each) — 26475P-08
  11. Stirrup & Clamp Kit — 22378G-15
  12. Retaining Ring (10/pk) — 00009M-03
  13. Left Dome — 15253P-11
  14. Boom Attachment Kit — 12840G-19
  15. Mic Boom Assembly — 18740G-34
  16. Microphone M-2H (150 OHM) — 09168P-76
  17. Mic Protector — 40062G-06
  18. Comm Cord Kit — 40599G-08

H8592 Item # 1 - 12

H8592 Item # 13 - 24

Electrical Schematic

David Clark H8592 Electrical Schematic

Comfort Upgrades Worth Considering for Your David Clark H8592

Looking to make your David Clark H8592 even more comfortable? These two upgrades are customer favorites:

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


The Double-Foam Head Pad Kit provides enhanced cushioning, reducing pressure points during long wear. This upgrade is particularly beneficial for the H8592, which is designed for extended use in professional settings.


👉 It's a simple, tool-free upgrade that significantly improves comfort.

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


These ear seals offer superior noise isolation and comfort, thanks to their gel-filled design. They are particularly effective in maintaining a strong acoustic seal, which is crucial for the H8592's noise-canceling capabilities.


👉 An excellent choice for those seeking to maximize both comfort and performance.

Maintenance Tips for Your David Clark H8592

  • Regularly inspect the Undercut Gel Earseal (40863G-02) for wear and replace if necessary to maintain optimal noise isolation.
  • Check the Comm Cord Kit (40599G-08) for any signs of damage or wear, as this can affect audio quality.
  • Clean the microphone protector (40062G-06) regularly to prevent dust buildup, which can degrade microphone performance.
  • Ensure the headband spring (15093P-03) maintains its tension to keep the headset secure and comfortable.
  • Store the headset in a protective case when not in use to prevent accidental damage.

By following these maintenance tips, you can ensure your H8592 remains in excellent condition, providing reliable performance for years to come.

Adapters for Your David Clark H8592


Enhance the connectivity of your David Clark H8592 with these compatible adapters:

Accessories to Enhance Your David Clark H8592

Complete your David Clark H8592 headset 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 H8592, including maintenance tips and parts breakdowns.
  • Maintenance Reminders: Helpful tips on when to replace ear seals, cords, and head pads to keep your H8592 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 H8592?

To replace the ear seals, remove the old seals by gently pulling them off the ear cups. Install the new Undercut Gel Earseal (40863G-02) by aligning and pressing them onto the ear cups.

What should I do if the microphone on my H8592 stops working?

Check the Mic Protector (40062G-06) for obstructions. If the issue persists, inspect the Mic Boom Assembly (18740G-34) and the M-2H microphone (09168P-76) for damage.

Can I use the H8592 with different communication systems?

Yes, the H8592 is compatible with various systems using the Comm Cord Kit (40599G-08), which allows for versatile connectivity.

How often should I replace the headpad on my H8592?

Replace the Headpad Assembly (18900G-45) when it shows signs of wear or becomes uncomfortable. Regular inspection will help maintain comfort.

What is the best way to clean the H8592 headset?

Use a soft, damp cloth to wipe down the headset. Avoid using harsh chemicals. For the microphone, ensure the Mic Protector (40062G-06) is clean.

Why is my H8592 headset only producing sound in one ear?

Check the Comm Cord Kit (40599G-08) for damage. Ensure connections are secure. If the issue persists, inspect the Earphone Assembly (10376G-89).

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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.