Question about MagLite Mag-Lite& Flashlight

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Mini Maglite _ Can't open battery housing to change batteries

I have a two AA cell mini maglite. The battery housing is at the end of the maglite opposite of the lamp end. The end cap will not unscrew so I can replace the dead batteries. Any tips on how to remove the end cap? We tried running under hot water and spraying on WD-40 with no success.

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  • Anonymous May 19, 2009

    Não consigo remover a tampa para substituir as baterias. O que faço? A minha lanterna é a MINIMAGLITE PRETA

  • Anonymous May 26, 2009

    Useless, tried all kinds of tools. The Mag company suggests leakage and will allow you to return your product.

  • Gene Park
    Gene Park Dec 22, 2013

    The bottom end is a cap. If it has a hole for a lanyard, stick a fork tine through the hole and gently turn. It may take half a turn then remove using fingers.

  • Gene Park
    Gene Park Dec 22, 2013

    At the bottom end is cap with a hole for a lanyard. Insert a steel fork tine and gently twist. This should break the seal and then remove the cap with fingers.

  • Anonymous Jan 04, 2017

    Useless, I even used two pipe wrenches and couldn't get the end cap off, ended up throwing it away.

  • Anonymous Apr 10, 2017

    Battery will have swelled and corroded, probably wouldn't have worked anyway.

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If there's a lanyard hole in the cap find something that will fit in that hole for leverage. If not you might have to use some vice grip pliers or two of them. There is a possibility that the batteries have leaked inside the light and has corroded the threads.

Posted on Dec 31, 2008

After messing with it for 45 minutes and scratching the heck out of it, my solution was to throw the dang thing away and use the flashlight app on my iphone.

Posted on Nov 04, 2012

  • picasso566
    picasso566 Nov 08, 2012

    I think that's what I'm gonna do thanks!

  • Leslie Thresher
    Leslie Thresher Dec 12, 2016

    Yes! Scratched the hell out of it ruined a good steel fork and royally peed off. Used to love maglites..hate using phone app...I have a black mini mag and the end cap opens like a dream... the newer silver one is friggin fused closed it seems. Never gonna buy one again.

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With all of the views on this problem, you would think that MagLight would
come up with a solution. I personally have had this happen to 2 different
flashlights. Never again will I purchase a Maglight!

Posted on Aug 09, 2012

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I applied a solvent (liquid wrench) overnight, and with a rod in the lanyard hole and vice clamp pliers, was able to remove the cap. But now I'm challenged with removing the corroded batteries so that I can get the battery manufacturer to replace the flashlight....I wish I knew, and had proof of what batteries are in there.

Posted on Jul 27, 2010

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I had luck using dental floss. I slid it between the joints and "flossed it" a bit, then unscrewed!

Posted on Mar 15, 2013

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I was able to open mine without scratching or damaging the case by clamping ordinary pliers, slipped to the wide-mouth setting, and an old leather glove. The pliers didn't cut the glove, and the glove didn't scratch the flashlight.

Posted on Jul 29, 2012

  • Ray Woodcock Jul 29, 2012

    I was able to open mine without scratching or damaging the case by
    clamping ordinary pliers, slipped to the wide-mouth setting, and an old
    leather glove. The pliers didn't cut the glove, and the glove didn't
    scratch the flashlight.

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I slipped an allen wrench into the hole for the lanyard and was able to unscrew it fairly easily. It was stuck because the batteries were severely corroded but I've had the thing for six or seven years so that's not a surprise. I should make a note to change the batteries every year or two.

Posted on Dec 14, 2015

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I put on WD-40, then used 2 vise grips & tried to twist it open but it wouldn't budge, so I put it through a table vise with cap upside, tightened vise and twisted hand grip to open and it worked. Then I wire brushed the cap and put the flashlight standing upright into a pot of boiling water with a teaspoonful of baking soda in it and left it soaking for 3 hours to dissolve the corrosion inside the battery compartment hoping to loosen the batteries inside. Haven't checked it yet but am hoping it a

Posted on Mar 18, 2015

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1 Answer

Replace batteries


Marcia Boal... hello,

If our battery has corroded it may be impossible to get the end (opposite the light) cap to come off. The light is designed to be moisture resistant... Likewise even penetrating oil cannot get in...

To guarantee long reliable service it is best to put a tiny dot of grease on the threads on assembly.

Maglite Solitaire makes a wonderful little flashlight...
(all metal construction... single AAA battery)...
((Mini = 2 AAA batteries... opens the same)).

Basic colors included black, red, silver & blue
but this particular light was also quite popular for commercialization... often displaying many BIG NAME
COMPANY LOGOs.

The initial closure of the end cap can be quite loose to be effective because of it's O-ring design... however some folks put the end cap on too tight...

The

It might take some serious force to get it open again.

Consider using a piece of leather in a pair of pliers to avoid marring the case. Reassemble without over-tightening.

Hope this helps!

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Tip

How to replace the lamp in a Mini Maglite


The Mini Maglite is a durable, compact flashlight. If your Mini Maglite stopped working, check or replace its two AA batteries first, and if that doesn't fix it, you'll probably need to replace the lamp. You can order replacement lamps in packs of two online, or you may be able to find them locally in a hardware store.

To replace the lamp in a Mini Maglite:

1. Unscrew the bottom of the flashlight. (Hold the flashlight with the head facing down so that the batteries don't fall out.)
2. Remove the batteries.
3. Unscrew the flashlight head from the barrel.
4. The lamp is mounted into the flashlight on two prongs; gently pull up on the lamp to remove it.
5. Install the new lamp by lining the prongs up with the two holes and slowly inserting it fully.
6. Screw the flashlight head back on.
7. Reinsert the batteries.
8. Screw the base back on.

When you've finished, turn the flashlight on (by turning the lens cover or the head counter-clockwise) to verify that the new lamp works. If the light doesn't come on, take the flashlight apart again and check to make sure the lamp is installed correctly and fully. Since the lamps come in packs of two, if you can't get the first lamp to work, try the second lamp in the pack. If that lamp doesn't work either, check your batteries and make sure the lens cover and head are both screwed on all the way.

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