Maglites have been around since 1979 and they are still going strong because they are some of the most durable flashlights ever made.
But like any other tool, they can break.
Luckily, they are easy to fix and parts are readily accessible.
In this tutorial, I'll show you how to fix everything that can go wrong with a Mini Maglite so you can get back to work as soon as possible.
Here's a list of everything that can go wrong with a Mini Maglite and how to fix it.
These instructions apply to both the Classic (Incandescent) and LED versions.
Here are all the reasons why the light won't turn on and how to fix them.
I suggest trying them in order because they go from least to most complex.
Yeah duh.
But for the sake of completeness, I have to include this step.
Some people may overlook it.
So pop in some new batteries and see if that works.
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The next thing to check is if the bulb is burnt out.
If you have the Classic version, you have 2 options:
To get the replacement bulb out of the tail cap, first, pull out the spring. Don't worry, you won't break it.
Then get some tweezers and pull out the orange plastic ring on the inside of the tail cap.
Inside the ring is the replacement light bulb.
Gently pull the bulb out and install it by pulling out the old bulb, then sticking the 2 prongs of the new bulb into the 2 holes in the switch.
Order a replacement bulb when you have a chance and put it back into the orange plastic ring, then put it back into the tail cap.
If you have the LED version, the only option is to buy a new bulb.
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A problem that I had with one of my Mini Maglites was one of the battery contacts was corroded.
This can happen when batteries leak inside the light, or moisture gets inside.
To fix this, first check the tail cap spring and switch for corrosion.
If either of them are corroded, then take some fine grit sandpaper and gently sand off the corrosion. Once you get down to the bare metal, you're done.
Put the flashlight back together and test it.
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If you did all of the steps above and the light still doesn't turn on, then the issue is going to be with the switch.
Simply buy a replacement.
Be sure to buy the correct switch for your flashlight. The switch is different for the incandescent and LED versions, so double check that you are buying the right one.
An easy way to tell which model you have is to look at the writing on the top of the flashlight. If it doesn't say “LED” then you have the incandescent version.
To remove the switch, first unscrew the tail cap and remove the batteries.
Then take out the part that holds the switch in place.
In the Classic version, this is the flat cap on the top. Pull that out with your fingers or a flat head screwdriver.
With the LED version, there is a ring that you pull out to free up the switch.
Once the switch is free, it will drop out of the bottom of the body.
Reverse the steps to install the replacement.
Resources
If you have this problem, then the issue is also with the switch.
It's either bent or stuck in the on position.
First see if you can play with the switch a little so that it goes back into place.
If not, then use the resources in the previous section to buy a new one.
Another common problem is that the battery can get stuck in the flashlight.
This happens because the battery expands or leaks because it's old or has been exposed to extreme conditions.
Luckily you can usually fix this and don't have to throw out the light.
First remove the tail cap and head assembly.
If you have a Classic Mini Maglite, then remove the bulb.
On both the Classic and the LED models, remove the cap that holds the switch in place. The cap on the Classic version is flat on the top and the LED version is a ring that is inserted into the switch.
Refer to the previous section for details on how to remove the cap.
Next, put a stick on top of the switch. A wooden stick would be preferable since it's softer.
Then gently pound the stick down with a rubber mallet to remove the stuck battery.
If you have the LED version, the bulb is attached to the switch, so you'll have to use something that will go around the bulb, so you don't break it.
This could be a wide metal straw or I've seen some people use a small socket with an extension.
Once the switch is removed, clean the inside of the body with a cloth or small screwdriver.
Reassemble and test.
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Parts that screw in like the tail cap can sometimes get dirty, making it difficult to unscrew them.
The fix is simple.
First, put a small amount of cleaning alcohol on a rag or paper towel. Then rub it on the threads of the affected parts to remove any buildup.
Once the threads are clean, get another cloth and put a small amount of lubricating oil on it. Rub the oil into the threads.
Don't use too much oil, or it will be a mess. A little goes a long way.
Now test out your work.
If you cannot get the threads clean, the consider buying a replacement part.
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If the lens on your Mini Maglite is scratched or broken, simply buy a replacement.
You can get either a plastic or glass lens.
I prefer plastic because it's lighter and less likely to crack. But glass in generally clearer and won't scratch as easily.
Unscrew the lens holder at the top of the head assembly, pop out the existing lens and put in the new one.
Screw the lens holder back in.
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If moisture is building up inside the Mini Maglite, the o-rings have to be changed because they are not sealing properly.
Replacements can be purchased from Maglite, or on eBay and Amazon.
There are 3 o-rings on the Mini:
To change an o-ring, roll or cut off the old ring. Then roll the new ring into place.
Once you have changed the o-rings, dry out the inside of the flashlight with a cloth or by leaving it out in a warm area.
Then reassemble the light and start using it.
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The Mini Maglite isn't as portable or have as many features as more modern flashlights.
But the simple, rugged design is timeless and these lights will usually last much longer than cheap plastic stuff from China.
I personally find it a little too big to carry in my pocket on the daily, but it's perfect for the glove compartment of a car or in a gear bag.
They can be purchased for a low cost and there are a ton of aftermarket parts, making it an ideal flashlight to have around the house.
As the saying goes…one is none and two is one.
So having a backup ensures that you'll always have a reliable Mini Maglite available when you need it.
Also remember to have enough AA batteries on hand to power your torch.
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