MagLite Camping, Backpacking & Hiking - Recent Questions, Troubleshooting & Support

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.

Carefully.....

Check in the base of the torch and you will see the spare bulb. you need to pull the spring out to get at it.
Next unscrew the top off the torch to expose the bulb.
The bulb is easily removed by gently pulling straight out. Replace the new bulb in the same way, lining the two pins up with the holes (doesn't matter which way round) and wipe the bulb clean of any finger grease etc.
Screw the top back on and replace the spring in the base before screwing the base back on..
Replacement bulbs, and all other parts for that matter, are easily sourced at any good outdoor store that stocks MAG.

Hope this helps..

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..

These are notorious for the switches failing. Mag will replace it for free if you ship it back to them.
Phone 909 947-1006

take the bottom piece off, remove the last battery and put a coating of petroleum jelly on the threads of the tube. Then take the bottom piece and run it all the way in and back off and back in 2 or 3 times. Then put a little more petroleum jelly on the threads and put the battery back in and the bottom piece. This should do it.

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.

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.

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