TE Connectivity 745994-4 D-Sub Connector Equivalent & Substitute Parts

Part Overview

The TE Connectivity 745994-4 is a 25-position D-Sub plug connector with right-angle solder termination, designed for through-hole mounting applications. This connector is classified as obsolete, necessitating identification of active equivalent and substitute parts for ongoing production and maintenance requirements. The AMPLIMITE HD-20 series connector features male pins, tin-plated steel shell, and gold-plated brass contacts suitable for signal applications with 6A current capacity and 125V voltage rating across an operating temperature range of -55°C to 105°C.

Substiute Parts

745994-4

TE Connectivity AMP ConnectorsIn Stock: 785745994-4 Datasheet

Current PartRFQ

5745994-4

TE Connectivity AMP ConnectorsIn Stock: 9355745994-4 Datasheet

DirectRFQ

625-025-662-012

Mercury United Electronics, Inc.In Stock: 1001625-025-662-012 Datasheet

DirectRFQ

183-025-113R171

NorComp Inc.In Stock: 2225183-025-113R171 Datasheet

SimilarRFQ

183-025-113R481

NorComp Inc.In Stock: 988183-025-113R481 Datasheet

SimilarRFQ

Key Parameters

Substitute Part Grouping Explanation

Substitution of the obsolete TE Connectivity 745994-4 is determined by strict alignment of the following critical parameters:

Primary Substitution Criteria:

• Connector style (D-Sub), type (Plug, Male Pins), and position count (25 positions, 2 rows)
• Shell size and layout (3 / DB, B)
• Mounting configuration (Through Hole, Right Angle)
• Termination method (Solder)
• Flange feature compatibility (Housing/Shell 4-40)
• Operating temperature range (-55°C ~ 105°C minimum)
• Material flammability rating (UL94 V-0)

Direct Equivalent: The TE Connectivity 5745994-4 is a direct equivalent, differing only in product status (Active vs. Obsolete), packaging format (Bulk), contact finish thickness specification (Flash vs. 30.0µin), and RoHS compliance status (Compliant vs. non-compliant).

Compatible Substitutes: The NorComp 183-025-113R171 and 183-025-113R481 maintain core D-Sub 25-position plug configuration, right-angle through-hole mounting, solder termination, and operating temperature range. These parts accommodate panel mount capability in addition to through-hole mounting and feature alternative shell finish (Nickel Plated) and dielectric material (Polyamide PA9T, Nylon 9T).

Limited Compatibility Substitute: The Mercury United Electronics 625-025-662-012 shares D-Sub 25-position plug configuration, right-angle mounting, and solder termination but operates at reduced current rating (3A per contact vs. 6A), lower maximum operating temperature (85°C vs. 105°C), and includes board edge mounting capability. Shell finish is Nickel Plated with Copper Alloy contacts and includes shielding features.

Parameter Comparison

Engineering Selection Recommendations

Primary Selection: TE Connectivity 5745994-4

The 5745994-4 is the recommended direct replacement for the obsolete 745994-4. This part maintains identical electrical and mechanical specifications, including 6A current rating, 125V voltage rating, and -55°C to 105°C operating temperature range. The primary advantages are active product status, RoHS compliance, and REACH unaffected classification, supporting modern supply chain and regulatory requirements. Packaging is supplied in bulk format.

Secondary Selection: NorComp 183-025-113R171

The 183-025-113R171 is suitable for applications requiring active product status and RoHS3 compliance. This connector maintains the 25-position D-Sub plug configuration, right-angle solder termination, and full -55°C to 105°C operating temperature range. The part accommodates both panel mount and through-hole mounting configurations. Current rating is 5A, which is acceptable for applications not requiring the full 6A capacity of the original part. Shell finish is Nickel Plated with Polyamide PA9T dielectric material.

Tertiary Selection: NorComp 183-025-113R481

The 183-025-113R481 provides an alternative with female screwlock mating-side flange feature in place of housing-side flange. This configuration is applicable when mating connector design requires screwlock engagement. Electrical and thermal specifications match the 183-025-113R171, with 5A current rating and -55°C to 105°C operating temperature range. RoHS3 and REACH compliance are confirmed.

Limited Compatibility: Mercury United Electronics 625-025-662-012

The 625-025-662-012 is applicable only for applications where reduced current capacity (3A per contact) and lower maximum operating temperature (85°C) are acceptable. This part includes board edge mounting capability and shielding features not present in the original connector. Backset spacing is 0.584" (14.84mm), representing a 0.16mm deviation from the original 0.590" specification. Selection of this part requires verification that application thermal and current requirements do not exceed specified limits.

Frequently Asked Questions (FAQ)

Q: Can the TE Connectivity 5745994-4 be used as a direct replacement for the 745994-4?

A: Yes. The 5745994-4 is a direct equivalent with identical connector configuration, pin count, mounting style, and electrical ratings. The primary differences are product status (Active vs. Obsolete), packaging format (Bulk), and regulatory compliance (RoHS Compliant vs. non-compliant). No design modifications are required.

Q: What are the key differences between the NorComp 183-025-113R171 and 183-025-113R481?

A: Both parts share identical electrical specifications, operating temperature range, and core D-Sub 25-position plug configuration. The primary difference is the flange feature: the 183-025-113R171 has a housing-side flange (4-40), while the 183-025-113R481 has a mating-side female screwlock (4-40). Selection depends on mating connector design requirements.

Q: Is the Mercury United Electronics 625-025-662-012 a suitable replacement?

A: The 625-025-662-012 is compatible for applications where current requirements do not exceed 3A per contact and maximum operating temperature does not exceed 85°C. The backset spacing deviation of 0.16mm and inclusion of shielding features require verification against application mechanical and electrical requirements. This part is not recommended as a direct replacement for applications requiring the full 6A current capacity or 105°C operating temperature of the original connector.

Q: What is the significance of the backset spacing difference in the 625-025-662-012?

A: Backset spacing defines the distance from the connector mounting plane to the contact engagement point. The 625-025-662-012 specifies 0.584" (14.84mm) compared to the original 0.590" (14.99mm), a difference of 0.16mm. This deviation may affect mating connector alignment and contact engagement. Verification against mating connector specifications is required before selection.

Q: Are all substitute parts RoHS compliant?

A: The TE Connectivity 745994-4 is RoHS non-compliant. The direct equivalent 5745994-4 is RoHS Compliant. The NorComp parts (183-025-113R171 and 183-025-113R481) are ROHS3 Compliant. The Mercury United Electronics 625-025-662-012 is ROHS3 Compliant. Applications subject to RoHS requirements should select from the compliant alternatives.

Q: What is the difference between "Flash" and "30.0µin (0.76µm)" contact finish thickness specifications?

A: Contact finish thickness specifications define the gold plating layer applied to brass contacts. The original 745994-4 specifies 30.0µin (0.76µm) thickness. The 5745994-4 specifies "Flash," indicating a minimal plating layer applied for corrosion protection without specified thickness. The NorComp parts specify "Flash" finish. Flash plating is suitable for signal applications and provides cost efficiency while maintaining contact reliability.

Q: Can the NorComp connectors be used in panel mount applications?

A: Yes. The NorComp 183-025-113R171 and 183-025-113R481 support panel mount, through-hole, and right-angle mounting configurations. The original 745994-4 and direct equivalent 5745994-4 support through-hole and right-angle mounting only. If panel mount capability is required, NorComp parts provide this additional flexibility.

Q: What is the current rating difference between the original part and substitute options?

A: The original 745994-4 and direct equivalent 5745994-4 are rated for 6A. The NorComp 183-025-113R171 and 183-025-113R481 are rated for 5A. The Mercury United Electronics 625-025-662-012 is rated for 3A per contact. Applications requiring the full 6A capacity must select the TE Connectivity 5745994-4. Applications with lower current requirements may select NorComp or Mercury alternatives.

Q: What packaging formats are available for these connectors?

A: The original 745994-4 packaging format is not specified. The 5745994-4 is supplied in Bulk packaging. The NorComp 183-025-113R171 and 183-025-113R481 are supplied in Tray packaging. The Mercury United Electronics 625-025-662-012 is supplied in Tray packaging. Packaging selection affects inventory management and component handling procedures.