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Most likley cause is that the batteries in the flashlight have leaked and has caused the threads on the end cap and flashlight to become fused. If at all possible, try to stand the end of the flashlight in a small plastic container with some PB Blaster, or other decent penetraiting oil, (WD-40 doesn't do very well in this situation).
After letting it soak overnight a good 24 hours, put the body of the flashlight into a vice, preferably with rubber or plastic jaws/protectors to keep from galling up the body of the light. Use a good sized pipe wrench to lossen the end cap and spray some penetrating oil onto the threads as you expose more, until loose. You will mark up the end cap, but you'll get it off. Once off, remove the batteries and use some baking soda to neutralize the battery acid. Rinse with water to clean and let dry. Remove any obstructions inside the battery tube with a wooden chopstick, or end of a wooden spoon (so as not to gouge or damage the aluminum tube) Get as much of this crude out and wipe dry.
You should be able to freely insert and remove the batteries, if not, keep cleaning the crude until the batteries go in and out easily.
Last ditch approach is to return the light to Maglight for them to repair and service. They'll return the light to you just like new, but there will be a charge for their service. Just check their web site for repair details.
Ok remember timing can be everything. Place in freezer overnight. When pulling it out use a glove or something as not to warm it with your hand. Place in vise and with a strap wrench or chain wrench along with a propane torch, in unison heat & turn. Brought to you by Strickland Propane and Hank Hill. Good luck.
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put the first one in positive side toward the light,, and the rest go in the same way, make sure the spring is attached to the base and screw it on, the positive side of the battery is the side with the bump on the end,, if it doesn't work after that ,, in the end cap of the flashlight you should have a extra bulb,, replace that and try it ,, be sure to put the spring back on the end cap
If yours is like all the ones I have had over many years the base cap unscrews by turning counter clockwise. They have a o-ring seal on the cap and some times they can be very tight. The housing is made out of aircraft grade aluminum and I have had one that was cross threaded at the factory and had to use pliers to get the cap off. Thank you.
A possibility that the batteries have leaked a caused a galvanic
corrosive issue, binding or fusing the end cap. See the manufactures instructions
for removing and installing batteries.
the batteries will only go out the bottom -- any attempt to remove the top pieces will most likely result in damage to the light itself. to help in the removal of the BOTTOM cap -- you can try and use a little heat from a propane torch ( not much ) and if you place the end cap into a vise you should be able to get both hands on the top part and give it a good twist. -- if the batteries are if fact corroded in there, get a 2x4 and place it on the gound and tap the flashlight down on it,, this may or may not shake them loose,, all just depends on how long they have been in there. good luck.
Remove the end cap by turning counter-clockwise and pulling cap off. It may be a pretty tight fit so you can wrap a rag around base cap and use pliers to loosen. Use rag or duct tape to protect finish on your light end cap. The threads are very fine so after you have removed end cap and replaced batteries be careful not to cross thread when reinstalling end cap. I hope this helps you. Thanks.
make sures its being turned to the left, and if it will not come off, wrap duct tape around it to protect it and use large vice grips or pliers to get it off. Vice grips would be better as the lock but dont' lock them down too tight as you can dent the cap.
Pull the cap off the end and wack it in your hand or a piece of wood, don't swing it like a baseball bat. Sometimes they get stuck in mine also, Not sure why, but a good wack gets the job done. Don't worry, the flashlight can take it.
Sprayed penetrating oil all the way around the end cap at seal area. Layed flashlight on it's side on a plastic block & tapped on housing just below the end cap with composite mallet while rotating. Then used aluminum jaws in a vise to hold housing while turning end cap with large pliers. Once cap is off, clean corrosion with automotive battery cleaner & soak inside with more penetrating oil to remove batteries.
Tonka Roy at Rosell Infiniti
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