How to Repair a Mini Maglite

Written by marshal m. rosenthal
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A Mini Maglite provides a powerful beam. A severe shock to the Mini Maglite's frame can dislodge the switch, making it impossible to turn on the light. You can repair the Mini Maglite by replacing the switch once you've purchased one from a Maglite supplies store. You do not need any special tools or electrical skills to replace the switch, although doing so will void any warranty in effect. The procedure should not take longer than a half hour.

Skill level:
Easy

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Things you need

  • Soft cloth
  • Needle nosed pliers
  • Flat-edged jeweller’s screwdriver
  • Flat-edged screwdriver
  • 5/16ths-inch Allen wrench
  • Mini Maglite switch replacement

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Instructions

  1. 1

    Unscrew the battery cap from the back end of the Mini Maglite and remove the batteries. Put the batteries and the battery cap on the soft cloth.

  2. 2

    Unscrew the reflector from the front end of the Mini Maglite and remove the retaining ring. Put the reflector and the retaining ring on the soft cloth.

  3. 3

    Clamp the jaws of the needle-nosed pliers around the upper left edge of the light bulb assembly peeking out from the front end of the Mini Maglite.

  4. 4

    Pull the light bulb assembly out with the needle-nosed pliers and place the assembly on the soft cloth.

  5. 5

    Insert the tip of the flat-edged jeweller’s screwdriver beneath the rubber switch button on the top of the Mini Maglite.

  6. 6

    Lift up on the tip of the screwdriver to loosen the rubber switch button. Pull the button off the Mini Maglite with your fingers.

  7. 7

    Insert the Allen wrench into the centre of the switch that is now revealed from under the rubber switch button. Rotate the wrench three turns counter-clockwise.

  8. 8

    Insert the tip of the flat-edged screwdriver into the front end of the Mini Maglite. Push the switch out of the back end using the tip of the flat-edged screwdriver. Discard the switch.

  9. 9

    Insert the replacement switch into the front end of the Mini Maglite.

  10. 10

    Push the replacement switch into the middle of the Mini Maglite using the tip of the flat-edged screwdriver. Stop pushing the replacement switch when the centre of the switch can be seen through the hole in the Mini Maglite where the rubber switch cover was.

  11. 11

    Insert the Allen wrench through the hole in the Mini Maglite and into the centre of the switch. Rotate the Allen wrench three turns clockwise.

  12. 12

    Put the rubber switch cover back onto the top of the Mini Maglite over the hole. Push down on the cover with your fingers to lodge it into place.

  13. 13

    Put the light bulb assembly back into the front of the Mini Maglite. Push down on the assembly with your fingers until it seats itself inside of the front end of the Mini Maglite.

  14. 14

    Put the retaining ring and reflector back onto the front of the Mini Maglite.

  15. 15

    Put the batteries back into the battery compartment and screw the battery cap back on.

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