Howdy. Just found this thread and thought I would stick my oar in. As you may have guessed, working at custom cans I have repaired quite a few pairs of HD25.
The issue with the connector is normally easy to fix. Inside the earcup sockets are two small springs which the HPSC ( two pronged ) connectors fit into. The crackle / lose connection has two causes.
1) The spring sometimes builds up some oxidization. This is why sennheiser clean the socket to fix them. You can normally fix it your self by plugging and unplugging the connector 5 - 10 times. This will wear away the oxidization and clear any dust / fluff and give you a good connection again.
2) The spring can develop a gap where the prong goes in. This is not as easy to fix and you need to be a bit brave.
A) You will need to remove the pad ( best to take the whole earcup off )
B) Take a small flat head screw driver and lift up the grill ( start where it is shown in the photo and work your way round ) It will un-clip safely just be carefull

C)
Carefully move the voice coil wires out of the way of the white plastic cap

D) Remove the plastic cap with some small pliers

E) Underneath you will find the offending springs ( Show here with the connectors plugged in to show how the socket works. Take your small flat head screw driver and stick it in the end coils and twist it to make the gap in the spring bigger at the ends and thus smaller in the middle where the pin clicks in. This will give it a nice tight connection
Then stick them back together.
Hope this helps

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