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Thread: Mag-lite Disassembly

  1. #1

    Default Mag-lite Disassembly

    How do you completely take apart a 3D Mag-lite?

  2. #2

    Default Re: Mag-lite Disassembly

    How do you completely read an instruction manual?
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  3. #3
    *Flashaholic* Marduke's Avatar
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    Default Re: Mag-lite Disassembly

    Quote Originally Posted by stephenmadpotato View Post
    How do you completely read an instruction manual?
    They don't come with complete disassembly instructions (including switch, removal of retainer clip, etc.).

  4. #4

  5. #5

    Default Re: Mag-lite Disassembly

    Marduke Thanks that is what I was looking for!

  6. #6
    Flashaholic* EvilLithiumMan's Avatar
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    Default Re: Mag-lite Disassembly

    Welcome to CPF

    Remove the head of the Maglite.

    Remove the tailcap.

    Remove the rubber switch cover. (Wash and dry your hands to help get a grip on the switch cover. Pinch and rotate the cover while pulling on it. It comes out fairly easy and also is not difficult to reinstall).

    Insert a 5/64" or 2mm hex wrench into the center of the switch plunger. Loosen the set screw that holds the switch assembly in place. (Trust me, it's there, but you never see it). Once the switch is loose, let it drop through the bottom of the tube.

    You can use the same wrench to disassemble the switch itself. Just be sure to pay attention to the placement of the two endcaps, spring and other components so you can reassemble it.

    I think there is info on Mag's site of all the components.
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  7. #7
    *Flashaholic* Burgess's Avatar
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    Default Re: Mag-lite Disassembly

    + 1

    for this info !



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  8. #8
    *Flashaholic* Patriot's Avatar
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    Default Re: Mag-lite Disassembly

    Quote Originally Posted by stephenmadpotato View Post
    How do you completely read an instruction manual?
    Not a very helpful response for a new CPF member dude....


    Sorry about that Beamshot. As you can see from the other posts, most people around here are much more helpful than the person who replied first. Also a warm welcome to you here at CPF
    Last edited by Patriot; 09-05-2007 at 11:09 PM.

  9. #9
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    Rant Re: Mag-lite Disassembly

    Quote Originally Posted by Patriot36 View Post
    Not a very helpful response for a new CPF member dude....


    Sorry about that Beamshot. As you can see from the other posts, most people around here are much more helpful than the person who replied first. Also a warm welcome to you here at CPF
    I must agree:

    Being sarcastic is one thing and can be fun at times. But answering a question with such a response that imposes the idea that you are trying to belittle someone, it is just rude. I believe you intentions were different, probably just for fun but sometimes you have to ease off. Some people might not understand the humor behind your statement.

    Last edited by djblank87; 09-06-2007 at 07:04 AM. Reason: Typo

  10. #10
    Unenlightened ricecookery's Avatar
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    Default Re: Mag-lite Disassembly

    Quote Originally Posted by EvilLithiumMan View Post
    Welcome to CPF

    Remove the head of the Maglite.

    Remove the tailcap.

    Remove the rubber switch cover. (Wash and dry your hands to help get a grip on the switch cover. Pinch and rotate the cover while pulling on it. It comes out fairly easy and also is not difficult to reinstall).

    Insert a 5/64" or 2mm hex wrench into the center of the switch plunger. Loosen the set screw that holds the switch assembly in place. (Trust me, it's there, but you never see it). Once the switch is loose, let it drop through the bottom of the tube.

    You can use the same wrench to disassemble the switch itself. Just be sure to pay attention to the placement of the two endcaps, spring and other components so you can reassemble it.

    I think there is info on Mag's site of all the components.

    Thanks for that ELM. I followed your directions and fixed all my "broken" Maglites. At first, none of the switches worked and I thought I had to buy new ones. Well, after taking apart each flashlite, disassembling and then reassembling the switches, now they all work.

    Who knew it was that easy to do.

  11. #11
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    Default Re: Mag-lite Disassembly

    Don't forget, Mags have a lifetime warranty! :P

  12. #12
    Flashaholic asfaltpiloot's Avatar
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    Default Re: Mag-lite Disassembly

    Here's a pdf file from Maglite.
    It's a step by step guide.

    http://www.maglite.com/pdf/CustServ/...2004324362.pdf

  13. #13

    Default Re: Mag-lite Disassembly

    Quote Originally Posted by djblank87 View Post
    I must agree:

    Being sarcastic is one thing and can be fun at times. But answering a question with such a response that imposes the idea that you are trying to belittle someone, it is just rude. I believe you intentions were different, probably just for fun but sometimes you have to ease off. Some people might not understand the humor behind your statement.


    ive gotten the cold shoulder here asking some newbie/stupid questions too but there are more than enough good guys around to offset them. nice to see helpfull resonses to the question, ive got several mags myself and didnt know how to dissassemble either. thanks !!!!!

  14. #14
    *Flashaholic* Burgess's Avatar
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    Default Re: Mag-lite Disassembly

    to 97guns --


    Welcome to CandlePowerForums !






    And to asfaltpiloot --

    Thank you for that PDF Link !



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  15. #15
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    Default Re: Mag-lite Disassembly

    You might find these exploded diagram photos helpful also:

    MagC switch assembly: (click for full resolution photo)

    MagD switch assembly: (click for full resolution photo)

  16. #16

    Default Re: Mag-lite Disassembly

    thankyou evillithiumman

  17. #17
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    Default Re: Mag-lite Disassembly

    Someone should also mention some of the newer Mags have been delivered with a set screw that requires a Torx T8 driver (w/a very skinny shaft) instead of the older 5/64" hex driver. (You should be able to search. Lots of discussion when it first started showing up, about a year ago?)

  18. #18
    Unenlightened
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    Default Re: Mag-lite Disassembly

    Hi all,

    My first post here. I found this site after much use of British Blades, and have become a little addicted to all things bright and shiny.

    I have an old 2D Maglite (without a "D" in the serial number). It has become very dirty after years of abuse in the home and car, and I have decided to give it a good clean, and replace the bulb with a Terralux LED jobbie.

    However, after following the instructions on this site, I am unable to budge the switch unit inside the tube. I have completely loosened the grub screw with a 2mm allen key but the switch will not come free.

    Should I resort to using force and hit it with a screwdriver and hammer? Or is there another solution?

    I also have a pair of Solarforce L2s; a Surefire E2 Executive; a Halcyon HID divelight and a MagCharger.

  19. #19
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    Default Re: Mag-lite Disassembly

    stretch3144, the older, pre 2001 D mags have a retainer ring in the head that has to be loosened.

    Bill

  20. #20
    Unenlightened
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    Default Re: Mag-lite Disassembly

    Quote Originally Posted by Bullzeyebill View Post
    stretch3144, the older, pre 2001 D mags have a retainer ring in the head that has to be loosened.

    Bill
    Thanks, Bill. I found the threaded ring and have loosened it off as far as it will go with needle-nose pliers. It seems to be stuck behind a grub screw and won't come out. The grub screw inside the switch has been fully loosened too. Not sure how to proceed now - have tried to push it out from the bottom but it will not budge.

    My intention was to convert this old 2D Mag into a ROP with a Pelican Big D bulb, and a pair of 18650 cells.

    Any further help would be appreciated.

  21. #21
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    Default Re: Mag-lite Disassembly

    Try pulling it out through the head.

    Bill

  22. #22
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    Default Re: Mag-lite Disassembly

    Apparently it is a snap ring and sort of difficult to remove. Use a needle nose plyers. I need to dig out my pre 2001 D mag and look at it if I can find it.

    Bill

  23. #23
    Unenlightened
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    Default Re: Mag-lite Disassembly

    One reason for wanting to disassemble a maglite is because the batteries have leaked and become stuck in place (I have a 4 D LED). Removing the switch is now not possible so one needs to be able to remove the spring clip in the head. This is the one critical operation not described here. Can anyone help with this part of the disassembly?

    Thanks, Dave

  24. #24

    Default Re: Mag-lite Disassembly

    If your Maglite has a spring clip it can be removed by putting a small screwdriver under one end and lifting it out of the slot that it's in. I've also read that a butter knife is the perfect tool. Never tried that. I've removed several with a screwdriver used as a lever. It's also possible to snag the end of the ring with a length of wire and pull it out. You could clean out the battery section and run a brake cylinder hone through the light to clean it up inside.

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