MagLite Camping, Backpacking & Hiking - Answered Questions & Fixed Issues

Stand it lens down and squirt WD40 down the gap and leave it standing overnight. That is the way the head comes off. My guess is that it is binding on the o-ring.

the spring has gotten weak that keeps the batteries tight together

It would be best if you visit the official of Maglite. It has all the required information which will solve your queries. The site has all the categories like spare parts etc.

This is the easiest answer I have found to date . Go to ; http://maglite.com/ and click " Support " . Follow the links from there ! Good luck . Alec .

Hello, you can find some video on youtube. https://www.youtube.com/watch?v=G8wmQKgOk7U Just type maglite dissasembly.

I'm gonna catch it for this but this is how I did it. Corroded batteries in the cylinder will eat and seize the aluminum threads on the end cap and it's pretty much toast after that. What I did was drill, yes drill a 0.125" (1/8") hole exactly .25" (1/4") above the seam between the end cap and the tube .0125" (1/8") into the tube. No more than that or you will jeopardize the integrity of the waterproof factor. Drop one drop of a quality penetrating oil, or even diesel fuel, into the hole every hour while randomly tapping the tube with a metal object to create a vibration to help the penetrating oil travel throughout the threads and dislodge the corrosive hold on your end cap. It might take a couple of days to loosen it up and try it with your channel-locks and a lined vice or strong wife. Just plan on gaining 1/32" movement and go back and forth until it gives up the grip. That process might take another day too. Keep adding the drop of penetrating oil along with the tapping religiously. It WILL work provided your patience holds out. Don't force it... well, not too much anyway. You can actually save it this way.

Alot of maglites are problematic with symptoms like this... I have found that the culprit many times is the screw cap on the bottom of the flashlight.
The elecrtrical connection needed between the spring in the end cap, the threads on the cap and the threads in the barrel of the flashlight...
Make sure you twist your spring a bit..the dissimilar metals can actually corrode between the spring and the cap... Then spin the threads a little... Then try the flashlight again...
This procedure may save yourself replacing a switch..

Not that I know of- they are usually 2 AAs. The 1 AAA keychain model was terrible in that the "turn to on" function was intermittent so I could never trust it. Tried WD40, sanding the contacts, etc. This was the old halogen version.

I have found a YouTube video that may help you. Search for:

Maglite® XL100™ LED Flashlight Demo

There's not much that can go wrong with the switch but things do happen.
I can tell you how to remove the SWITCH then you can go to www.maglite.com to order a new switch if you then think that's what the problem is. However, I do not know how to actually 'test' the SWITCH itsself to determine if it is defective. I have the rechargeable model which is nearly 20yrs old and it developed the same issue about 10yrs ago. I simply removed the old switch, ordered a new one, installed it and now have a happy light.
Let me know and I will send you instructions. :)

when you dropped it you probably knocked the contacts inside out of place. or you broke a soldered connection. if you can take it apart you can most likely fix this yourself. when you remove the front lens assembly there is a retaining clip that you need to remove so you can take the guts out.....please rate this

Yes , Matco and snap on tool trucks can sell you switch and show you how. , or farm and fleet stores .

Make sure you cleaned ALL the corrosion out of the battery cell, and also you may have a faulty On/Off button.?The battery contacts must be absolutely clean.That is my best assumption

well, I have a 3 cell mini maglite AA with a corroded battery stuck up next to the LED. I have searched but not found a way to remove the LED to push out the battery with a dowel. The best solution I read about was to drill a hole in the battery and insert a large screw and pull it all out. (My Maglite is from 2009 or 2010, but I think they made this model in 2011, 2012 and 2013- this is for SEO!)

yes the bulb assy can be removed as it's basically the switch you need like a special tool for removing it. but first which brand of battery is in it. both energizer and Duracell have warranty about replacing item that the battery has damaged. try that route is my suggestion before trying to remove batteries and possibly breaking the switch. you can get one sent to you by calling up customer service as i replaced one before mini mag lite also.

Volt meter. Touch one lead to each contact. If you dont have one Harbour Freight has on for around 5.00.

Should be able to get it with tweezers or needle nose.

SOUNDS LIKE IT IS CORRODED. PUT A FEW DROPS OF RAPID TAP TAPPING FLUID OR A FEW DROPS OF THIN MACHINE OIL AROUND THE CAP. LET IT SIT FOR A FEW DAYS AND TRY IT AGAIN.

mine came with the pushbutton battery end replacement to turn on\off rather than twisting the reflector end. You can not have the reflector end screwed all the way in, this still turns the light off. You have to back the reflector end off a tad from being all the way in, then use the pushbutton to turn it on/off.

This has happened to me several times. You can begin removing the bulb and reflector from its end of the flashlight. I then get a very long (5 or 6 inch) deck screw, the kind that has very coarse wood screw type threads. I screw this into the swollen battery (you may need to drill a small diameter pilot hole in the botton of the battery) and pull on the screw with pliers to see if the battery will budge. If it wont budge, I then stand the flashlight with the battery compartment up, fill it with water, leave it overnight, drain the water and pull on the deck screw again, this usually removes the battery.
NOTE: The magnesium in these flashlights rapidly corrodes away in the presence of battery leakage, so if the battery has leaked a lot, you may be left with only the undamaged components to use as spare parts to repair other lights.
ALSO: If you batteries have a no-leak guarantee, contact the manufacturer' customer service for your free Maglight.