Switch Removal

Not so long ago while doing a Handyman job I was lucky enough to be given a double D cell Maglite by a customer.

I was told that the Maglite didn't work but that didn't faze me too much at the time after all it was free and looked like new.

later I inserted new D Cells in the torch pushed the switch and apart from the audible click of the switch there was nothing, not even a glimmer. I changed the bulb (a spare is located in the screw off end cap) but still no light, my multi meter confirmed that although there was a positive (+) feed the negative (-) wasn't making it to the bulb regardless of the switch position. So obviously the switch was faulty.

Now we all know that a Maglite is a well made bit of kit and when you look at one closely it is even more evident.

The switch is located well inside the tube with just the bulb part and the switch button protruding, getting at the switch is all but impossible.

I searched the internet and came up with some instructions and made the recommended tool to remove the switch but to no avail. It turns out that there are two types of D cell Maglite and mine is the new type. Using the tool all I managed to do was break away the little fins that support the bulb tube and rub up the plastic on the end of the switch (see photo's).

Another friend eventually told me how to remove the switch, this is how you do it.

This will only work with Maglite's that have a Serial Number preceded by a letter D (looks like an O sometimes) this also works with 3 and 4 Cell torches.

 

Remove both ends and it is a good idea to remove the bulb as it might be broken but I didn't.

 

Remove the rubber button, this you can do with a finger nail inserted at the edge it should then peel away and pull out.

Take a 2mm Allen Key

Insert the Allen Key it into the hole in the center of the switch you should feel it locate into a grub screw deep in the hole.

Turn the key clockwise and you should feel the grub screw undo and become loose you will feel some resistance but don't force it.

The switch should then be loose in the tube, but ensure that it is in the on (pushed in) position and it will then slide out of the battery cap end, sometimes they can be tight in the tub so you may need to gently push it out with something. Remove the bulb first though.

 

 

Here you can see the grub screw that you have just undone.

You can see the damage to the fins here, Do not use the Maglite tool on these torches.

Reassembly is not hard to do, the switch lines up with the hole easily and with a bit of fiddling you can get the grub screw to screw back into it's hole.

The rubber button cover can be troublesome but it will go in eventually.

 

You can get replacement switches, eBay is a good place to start, or try the advertisers on this page, a Maglite dealer should be able to help.

As it turned out when I reassembled my Maglite it worked straight away I think that the Grub screw was either dirty or loose (it serves as the Negative connection)

Good Luck !