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How to Fix a Mini Maglite

Updated November 21, 2016

The Mini Maglite is a small aluminium-body flashlight produced by the Mag Instrument company. Part of the overall line of Maglite flashlights, the Mini Mag uses two AA batteries as a power source. The beam is controlled by rotating the threaded head to the left and right, and the head of the flashlight can also be completely removed and it can be used as a candle. Mini Mag flashlights, although designed to be durable, can require basic repair from time to time.

Hold the aluminium tube of the flashlight body and turn the tail cap to the left to loosen and remove it. Turn the flashlight tube over to empty out old AA batteries.

Look into the body of the flashlight and locate the battery contact at the base of the tube. Insert the eraser end of a pencil into the tube and rub the contact to remove any corrosion.

Pour a small amount of denatured alcohol on a rag and wipe the threads on the end of the Mini Mag tube to remove metal or other debris that could interfere with sealing the light. Wipe the threads on the inside of the tail cap with alcohol also.

Unscrew the head of the flashlight from the tube. Inspect the O ring for damage and clean it with a rag and water. Remove the O ring and use the damp rag to wipe away any oils or debris.

Apply a thin film of silicon grease to the O ring and place it back on the flashlight. Also apply a thin film of grease to the threads for lubrication.

Replace the bulb of the Mini Maglite by firmly gripping the bulb and pulling straight out and away from the lamp assembly located on the forward end of the light.

Hold the tail cap, pull out the spring and remove the spare bulb. Insert the new bulb into the lamp assembly by aligning the contacts and pushing the bulb straight into the assembly. Screw the head assembly back onto the front of the flashlight.

Place new AA batteries in the flashlight with the positive ends toward the front of the light. Screw on the head and tail cap securely.

Things You'll Need

  • Pencil with eraser
  • Denatured alcohol
  • Rag
  • Silicon grease
  • AA batteries
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About the Author

Keith Dooley has a degree in outdoor education and sports management. He has worked as an assistant athletic director, head coach and assistant coach in various sports including football, softball and golf. Dooley has worked for various websites in the past, contributing instructional articles on a wide variety of topics.