I gave Safety Equipment Technical Services a call yesterday as I need some new foam tips and also a new set of ear pieces. Unfortunately if the wire breaks close to the ear piece, it seems unrepairable. The prices he quoted me were more than double the prices quoted from the supplier in the States. So best to order from the supplier.
I find them a great asset in the back of the helicopters and now can't live without them.
I have made a repair to the broken ear piece by soldering an "in the ear" headphone off a normal personal stereo.
Eagle 86, have had the same problem with the male fitting, you just have to be gentle (unlike your keyboard pounding) when removing the plug.
I found a small plastic cable tie keeps it secure.