My D60 flash problem was that the flash would pop up, but would not flash. The release lever would keep "clicking"...it did no know that the flash was up. Since I was told that the min cost of sending it to Nikon for repair was $250, I downloaded a repair/service manual for the D60 from http://www.tradebit.com/filedetail.php/9029672-nikon-d60-service-repair-manual ($8.99)
This manual gives a step by step assembly and disassembly of the camera.
I actually lucked up and fixed my problem...
Problem Descripton/Solution (short version):
There was a tiny plastic collar at the flash hinge that got pushed back into the camera. This collar served to close a couple of contacts. I stuck a home made wire/double hook tool into the hinge clearance hole and pulled the collar out and snapped it back into place.
Problem Description/Solution (LONG version)
WARNINGS (based on experience)
1. Yes, the flash will still shock the **** out of you..even with the battery out. You will smell burnt hair/flesh.
2. Be careful of the tiny contact leaf springs. They are hard to bend back into the correct position.
3. The #00 screws are easy to strip out. Apply firm pressure, turn slowly, and make sure screw driver is aligned properly.
4. Proceed at own risk (to camera). Make sure your warranty really has run out. There are many ways to make things worse. You can back out now and buy an external flash.
All I had to take apart however was the top cover of the flash (two tiny screws on underside of the flash #00 philips head). I found that there are two tiny copper or gold "leaf spring" contacts that have to close to send a signal that the flash is up. These are located at the hinge where the flash wiring runs into a clearance hole into the camera (hole is a center of rotation of the flash). There is a small plasitc collar that fits into this clearance hole from inside the flash/camera base and through the flash housing at the pivot point and snaps into place via 2 plastic hooks or tabs (download/see repair manual). This collar serves to secure the flash housing to the base but also has a tiny pin sticking out that catches one of the contact leaf springs and closes the circuit. The problem is that this collar got knocked out of place and pushed back into the camera. I made a home made wire/double hook tool out of 22 gauge wire (see attached picture) and worked it into the clearance hole by pinching the hooks together and working it in. Go in above the flash wires (top of hole) since the wire path goes downward into the camera. With some work and luck I was able to hook the edge of the collar and pull it back out and snap it back in place.
I then put the flash cover back on and everything still seems to work.
My Hook Tool....
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