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Metz 45-40 consist of 6 nos of NiCd - AA size batteries connected in series.
These battery packs can be rechanged by resoldering new set of AA size rechargable Nicd battries.
Care should be taken not to short circuit the cells when disassembling and assembling the cells.
Keep a note (sketch) of the connections of the cells, specially the longer connecting metal strip and the polarities of cells.
re-solder the new set of AA size NiCd Batteries.
If the old wires were corroded, use new wires'
If the connecting terminals also corroded' clean it.
If it is severely corroded, get it plated prior to fixing for better performance..
There is an charging indicating lamp which also control the charging current of the batteries.
check its connections and solder it if required.
I wish you got the answer for your problem.
Regarding using the Sunpak 4000AF flash with my Canon EOS Digital Rebel, I can't get the flash to fire. There seems to be no combinations of settings that works to make the flash work. Could a weak battery in the Canon cause this? Does it require some other wire connector between the flash and the camera?
I know this is old technology now, I have a pocket digital for most of my uses, but I'd like to try bounce flash again on my old Rebel digital, and so I've gotten out my old camera and the flash I had bought for it. I had bought the Sunpak flash years ago and I honestly don't remember if I got it to work back then or not.
If you know basic soldering, Open the old hot shoe from base (4 screws).Note down the position of the wires. Try to fire the flash with shorting two trigger wires,most ly it will fire. If the springy contact is adjustable do it.If it is not repairable, you can get metal hot shoe from ebay easily. Caution: metal hot shoe will short circuit 4 TTL contacts (on digital camera) ,so you need to put cello tape at bottom of hot shoe with only center hole. Hope this solves.
Do not put the camera in P mode, it must be in M. Also some of the old Novatron units have a polarity issue. If the Camera cannot fire the Novatron, that the plug out of the Novatron in turn it 180 degrees then plug it in again. Sometime on older units this fixes the problem because the voltage polarity is not matched.
That particular unit is probably not a good choice for the D80 because the trigger voltage (the electricity which flows from the flash through the camera circuits to fire the flash) is 19.5 volts, according to http://www.botzilla.com/photo/strobeVolts.html - this could possibly damage your camera electronics.
You don't have to stick with Nikon brand Speedlights, but get a modern flash which says it is I-TTL compatible for Nikon.
It will take some fiddling around with very small parts to get that installed.
Or you can send it in to Olympus- I know a couple of people that have been charged ~$50 for the repair and Olympus also reconditions everything as well.
Try to short out the flash and see if the flash flashes.
Remove flash from camera.
New or fresh bateries installed.
Get wire with insulation and remove both end bare to 1/4"
Turn on flash and wait until light turn green or ready.
Touch one lead to center of flash pin, touch other end to the outside(rail on the side) pin.