Telex 5x5 Pro III Headset Parts Guide & Illustrated Catalog

The Telex 5x5 Pro III is a lightweight, single-sided aviation headset designed for pilots who prioritize clarity, comfort, and minimal weight during flight. Known for its unique eartip-style receiver and flexible wearing configurations, it has long been a popular choice in quieter cockpits and training environments.

Although the Telex 5x5 Pro III was discontinued in October 2025, many pilots continue to rely on it daily. Proper maintenance and access to genuine replacement parts are essential to keeping this headset performing reliably.

In this guide, we’ll break down the headset’s features, specifications, and provide a complete illustrated parts catalog along with available replacement parts and maintenance tips — all supported by Pilots HQ, your trusted source for Telex headset parts and accessories.

• Ultra-lightweight design reduces fatigue on long flights

• Eartip-style audio provides clear communication in low-noise environments

• Flexible wearing options (headband or eyeglass-mounted)

• 180° rotating microphone boom for left or right-side use

• Proven reliability with FAA TSO-C57 and C58a approval

• Weight: ~2.3 oz (65 g) on-head (ultra-lightweight design)

• Configuration: Single-sided aviation headset

• Receiver Type: Magnetic

• Microphone: Noise-canceling electret with built-in amplifier

• Frequency Response: 100 Hz – 3 kHz

• Speaker Impedance: 600 Ω

• Microphone Sensitivity: -48 dB re 1 V/μbar @ 1 kHz

• Cord Length: ~5.5 to 6.6 ft (varies by model)

• Connector Types (by model):

  • Dual GA (PJ-055 & PJ-068) – 64000-100

  • PJ-068 single plug – 64000-102

  • PJ-051B – 64000-103

  • XLR-5-12C – 64000-111

  
  

• Power Requirement: Via aircraft microphone circuit (no external battery)

• TSO Approval: C57, C58a

• Warranty (original): 3 years

The Telex 5x5 Pro III was offered in several configurations, primarily differing by connector type and cord setup.

Key models include:

• 64000-100

  • Dual GA plugs (PJ-055 & PJ-068)

  • Most common configuration for general aviation

  
  
  
  

• 64000-102

  • Single PJ-068 plug

  • Typically used in specialized or modified aircraft setups

• 64000-103

  • PJ-051B plug configuration

  • Less common, used in specific installations

• 64000-111

  • XLR-5-12C connector

  • Designed for select panel-powered or integrated systems

  • Not equivalent to Airbus XLR or LEMO standards

  
  
  
  

All versions maintain the same core features:

• Lightweight single-sided design

• Eartip audio system

• Amplified noise-canceling microphone

• FAA TSO C57 / C58a approval

Choosing the correct model is critical, as connector differences directly impact compatibility and performance.

Because this headset uses an internally powered microphone amplifier, connector compatibility is more complex than standard passive headsets.

• Not all adapters will work correctly

• LEMO (6-pin) and Airbus XLR systems are not directly supported

• Even XLR versions are not universally compatible with Airbus wiring standards

For best performance, pilots should use a version of the headset that matches their aircraft’s installed connector, rather than relying on adapters.

The Telex 5x5 Pro III uses an in-ear eartip audio system rather than traditional over-ear ear cups. This design delivers excellent speech intelligibility, especially in quiet to moderately noisy cockpits, such as training aircraft or general aviation environments.

Because it does not rely on passive earcup sealing or active noise reduction, this headset is best suited for pilots who prioritize lightweight comfort and communication clarity over maximum noise attenuation.

This guide focuses on the most commonly supported Telex 5x5 Pro III -100 series configurations, including model 64000-100, which represents the standard dual GA version widely used in general aviation. The parts, components, and replacement items listed throughout this article are based on this configuration and reflect the most relevant serviceable items pilots typically need for maintenance and repair.

For less common configurations, including alternate connector variants and internal component-level servicing, Telex provides additional documentation through the official Component Maintenance Manual (CMM). This manual includes detailed diagrams, internal assemblies, and expanded parts breakdowns beyond standard field-replaceable items.

If you are working with a non–100 series model or require deeper technical servicing information, we recommend referencing the official component maintenance manual to ensure proper identification and compatibility of parts.

Pilots HQ continues to support the Telex 5x5 Pro III with available replacement components and guidance to help extend the life of this discontinued headset.

1. 51845-037 – Screw, No. 4-40 x 3/16
2. 50014-002 – Washer, Lock
3. Clip, Headband/Eyeglass
   • 64001-013 – for 64000-100
   • 64001-014 – for 64000-101
   • 64001-015 – for 64000-102
   • 64001-016 – for 64000-103
4. 56016-004 – Screw, No. 0-80 x 3/16
5. 63096-000 – Sleeve, Threaded
6. 53850-000 – Nut, Square, No. 4-40
7. Receiver Assembly
   • 63977-000 – for 64000-100, -102, -103
   • 63977-001 – for 64000-101
8. 35629-009 – Eartip Assembly
9. Microphone Assembly, Boom
   • 800126-000 – for 64000-100, -102, -103
   • 800126-002 – for 64000-101
10. 63097-002 – Clip Assembly, Clothing
11. Cord Assembly
    • 70413-001 – Y Cord Assembly for 64000-100
    • 70413-000 – Y Cord Assembly for 64000-101
    • 64249-000 – Cord Assembly for 64000-102
    • 63988-016 – Cord Assembly for 64000-103
12. 600019-000 – Amplifier Assembly
13. Housing, Receiver/Amplifier, Top
    • 63976-007 – for 64000-100, -101
    • 63976-006 – for 64000-102, -103
14. Housing, Receiver/Amplifier, Bottom
    • 63975-002 – for 64000-102, -103
    • 63975-004 – for 64000-100, -101
15. Headband Assembly
    • 63993-001 – for 64000-102, -103
    • 63993-000 – for 64000-100, -101
16. 63575-000 – Cushion, Headband (2 required per headset)
17. 63997-000 – Headpad Assembly, Pivot Arm
18. 63563-000 – Headpad Assembly, Right
19. 51845-004 – Screw, No. 2-56 x 5/16
20. 52188-004 – Nut, Hex
21. 50014-009 – Washer, Lock, No. 2
22. 63998-000 – Washer, Nylon
23. 64003-000 – Glider
24. 63994-000 – Housing, Headband Spring Retainer
25. 63556-000 – Spring Assembly, Headband
26. 63124-023 – Foam
27. 59798-010 – Access Hole Cover, Black

To keep your Telex 5x5 Pro III performing at its best:

• Replace eartips and tubing regularly to maintain audio clarity

• Inspect microphone position (should sit close to the lower lip)

• Check cord strain and plug condition

• Replace headpad cushions when worn

• Store in a protective pouch when not in use

Routine maintenance significantly extends the usable life of this discontinued headset.

Recommended Upgrades for Telex 5x5 Pro III Pilots

If you're replacing your Telex 5x5 Pro III, modern Telex headsets offer improved comfort, better noise management, and more configuration options. The right upgrade depends on whether you want to maintain a lightweight setup or move to a higher-performance dual-ear design.

Single-Sided Upgrade Options

Telex Airman 750
A lightweight dual-ear headset that offers better passive noise reduction than in-ear systems. This is a strong step up for pilots moving from the 5x5 Pro III into a more traditional headset design without adding significant weight.

Telex Airman 8+
The most advanced option in this lineup, the Airman 8+ adds active noise reduction and enhanced audio clarity. It’s ideal for pilots flying in louder aircraft or those looking for reduced fatigue during long flights, while still maintaining a lightweight feel.

Telex Airman 8
A balanced option that delivers lightweight comfort and clear communication without full ANR. This headset is well-suited for pilots who want a modern Telex design while keeping cost and complexity lower than ANR-equipped models.

Telex Airman 850 ANR
For pilots prioritizing maximum noise reduction, the dual-sided Airman 850 ANR provides stronger noise attenuation and improved communication clarity in high-noise cockpits. This is the best choice for those transitioning away from lightweight in-ear designs to a more robust, high-performance headset.

Upgrading from the 5x5 Pro III allows you to choose between maintaining a lightweight setup or improving noise reduction and comfort for more demanding flying environments.

Even though the Telex 5x5 Pro III has been discontinued, many pilots continue to rely on it for daily use. Keeping these headsets operational requires access to the right parts, accurate information, and ongoing support.

Pilots HQ specializes in helping pilots maintain and extend the life of legacy aviation headsets like the 5x5 Pro III. From commonly replaced components like eartips to harder-to-source parts, our team can help identify what you need and guide you through replacement options.

We also provide detailed parts guides and compatibility insights so you can make informed decisions about repairs, upgrades, or replacement headsets when the time comes.

• Support for discontinued Telex headset models
• Access to replacement parts and sourcing assistance
• Clear guidance on compatibility and configurations
• Educational resources to help extend headset life
• Pilot-focused service from an aviation-specialized team

Whether you're maintaining your current headset or planning an upgrade, Pilots HQ is here to support you at every stage.