TE Connectivity 745496-5 D-Sub Connector Equivalent & Substitute Parts

Part Overview

The TE Connectivity 745496-5 is a 25-position D-Sub plug connector with male pins, designed for IDC (Insulation Displacement Contact) and discrete wire termination. This connector belongs to the AMPLIMITE HDE-20 series and features a free-hanging, in-line mounting configuration with a DB/B shell size layout.

The 745496-5 is classified as obsolete. Locating equivalent and substitute parts is necessary to support legacy system maintenance, repair, and component replacement in applications where this connector is currently deployed.

Substiute Parts

745496-5

TE Connectivity AMP ConnectorsIn Stock: 932745496-5 Datasheet

Current PartRFQ

1-745496-8

TE Connectivity AMP ConnectorsIn Stock: 18111-745496-8 Datasheet

DirectRFQ

Key Parameters

Substitute Part Grouping Explanation

Substitution of the 745496-5 is determined by strict equivalence across all critical electrical and mechanical parameters. The substitute part must match the following criteria:

• Connector style, type, and pin configuration (D-Sub plug, male pins, 25 positions, 2 rows)
• Shell size and layout (Size 3, DB/B configuration)
• Mounting method (free hanging, in-line)
• Termination capability (IDC and discrete wire support)
• Wire gauge compatibility (22-26 AWG)
• Electrical ratings (250V voltage, current rating varies by wire gauge)
• Operating temperature range (-55°C ~ 105°C)
• Shell material and finish (steel, tin plated)
• Contact material and finish (phosphor bronze, gold plated)
• Dielectric material (thermoplastic, glass filled)
• Flange configuration (unthreaded housing/shell)
• Grounding indents feature
• Flammability rating (UL94 V-0)
• Moisture sensitivity level (MSL 1)

The substitute part 1-745496-8 meets all these criteria and is therefore a direct functional equivalent.

Parameter Comparison

Engineering Selection Recommendations

The 1-745496-8 is a direct functional equivalent to the 745496-5 across all critical electrical and mechanical parameters. Both connectors are manufactured by TE Connectivity within the same AMPLIMITE HDE-20 series and share identical specifications for connector configuration, termination capability, voltage rating, temperature range, and material composition.

The primary distinction between these parts is product status and regulatory compliance. The 745496-5 is obsolete and RoHS non-compliant, while the 1-745496-8 is an active product with ROHS3 compliance. The 1-745496-8 also features a thicker gold contact finish (30.0µin versus 1.00µin), which provides enhanced durability and contact reliability.

For new designs and ongoing system support, the 1-745496-8 is the appropriate selection. For legacy system maintenance where the original 745496-5 is specified, the 1-745496-8 provides full functional compatibility with improved regulatory compliance and contact durability.

Frequently Asked Questions (FAQ)

Q: Can the 1-745496-8 be used as a direct replacement for the 745496-5?

A: Yes. The 1-745496-8 is a direct functional equivalent. Both connectors share identical electrical and mechanical specifications, including connector type, pin configuration, shell size, termination method, voltage rating, temperature range, and material composition. The 1-745496-8 is the active product variant and is fully compatible with applications originally designed for the 745496-5.

Q: What is the difference in contact finish thickness between these parts?

A: The 745496-5 has a contact finish thickness of 1.00µin (0.025µm), while the 1-745496-8 has a contact finish thickness of 30.0µin (0.76µm). The thicker gold plating on the 1-745496-8 provides enhanced contact durability and resistance to wear during mating cycles.

Q: Are there packaging differences between the 745496-5 and 1-745496-8?

A: The 1-745496-8 is supplied in bulk packaging. The packaging specification for the 745496-5 is not provided in the technical data. Packaging differences do not affect functional compatibility or electrical performance.

Q: What is the significance of the RoHS compliance difference?

A: The 745496-5 is RoHS non-compliant, while the 1-745496-8 is ROHS3 compliant. ROHS3 compliance indicates the 1-745496-8 meets current regulatory requirements for restricted hazardous substances. For applications subject to RoHS regulations, the 1-745496-8 is the required selection.

Q: Can both parts support IDC and discrete wire termination?

A: Yes. Both the 745496-5 and 1-745496-8 support IDC (Insulation Displacement Contact) and discrete wire termination methods. Both are compatible with wire gauges 22-26 AWG.

Q: What is the operating temperature range for these connectors?

A: Both connectors operate across the temperature range of -55°C to 105°C, making them suitable for industrial and harsh environment applications.

Q: Are these connectors suitable for high-voltage applications?

A: Both connectors have a voltage rating of 250V. The current rating varies by wire gauge. Verify that the wire gauge and current requirements of your application align with the connector specifications.