Mini Maglite Flashlight. How to remove corroded and stuck batteries

[@wystearya4347]

You just helped me fix a very old Mini Maglite that my late father had given to me years ago. Thank you so much!

[@Tobinindustrial]

I am glad this video was helpful to you. It is great to have your late father's light back to functional again.

[@wystearya4347]

@@Tobinindustrial Yes it is! I was very upset about the stuck battery. I knew there had to be a way to get the lightbulb end off, I just didn't know how. I still need to clean the corrosion from the inside of the tube, but I did a quick test and it does work! Duracel is also the battery that stuck for me. Not sure I will use them again in my Maglite. Thanks again!

[@Tobinindustrial]

@@wystearya4347 I have switched to Everready batteries in mine and in any similar narrow shafted pen light. No issues since.

[@wystearya4347]

@@Tobinindustrial Funny enough, my Dad's cat's name was EverReady. I won't forget to use those!

[@andygold]

Recently found a MagLite AA I gave my daughter years ago. It was dead, with the batteries corroded inside. No amount of rapping on the end cap side would dislodge them. I removed the head/reflector assembly and bulb, laying them aside. I placed the body tube with stuck batteries, along with the corroded end cap (I removed the spring and spare bulb first) in a sandwich size zip lock bag, which I then added white vinegar to and left it for the better part of a day, occasionally giving it a good shake. The battery tube will easily lay across the bottom of the bag, and I only needed to use about an inch of vinegar, just enough to fully submerge the body tube laying across the bottom of the bag. After about 24 hours, the vinegar had turned from clear to white, as it broke down the corrosion. A few taps on the end of the tube and the first battery easily slid out. I needed to reinstall the end cap to give some more forceful taps to get the second battery to loosen up and slide down (cap was reinstalled to protect the tube's threads/opening from being damaged). If you are going to be rapping the end cap, I'd suggest you first removed the hidden spare bulb that resides below the end cap spring.

[@Tobinindustrial]

Awesome repair my friend. Yes, there is a spare bulb under the spring. Your vinegar idea makes perfect sense.I was thinking that a coke or pepsi drink would also work great but vinegar is very strong and did the trick. congratulations on the salvage of your daughter's flashlight.

[@patriceblanchard5111]

Thanks Andy, after reading you I put my mag light 2 days in white vinegar . Than I was able to push the plastic piece on top to remove corroded battery.

[@patriceblanchard5111]

@@Tobinindustrial, thanks for your video that showes me how to disassemble the mag lite

[@Tobinindustrial]

@@patriceblanchard5111 Happy to be helpful. God bless you.

[@victorpeters589]

Hi, I came across your video when searching for a solution to remove stuck AA's from my MagLite Mini. Thanks to your video I was able to disassemble the front of the MagLite and remove the battery closest to the lightbulb on the front. The AA's were a bit moist on the outside, so I used an old toothbrush and a cleaning cloth (part of an old t-shirt) and cleaned the inside of the barrel as well as I could. The ground pin sits fairly loose and when assembling the MagLite it kept falling out of the unit that goes into the front of the flash light. But holding the flashlite upright and pushing the assembled front unit (with the ground pin installed) upwards with two new AA's I was able to get the front unit to where it needs to be. THe rest was easy. And now I have a working flashlite again. Thanks for your video.

[@Tobinindustrial]

I am so happy that the video was of good use to you. You certainly did an awesome job in preserving the flashlight. Too much of anything and the flashlight can be rendered useless. Thank you for the channel support and God bless you.

[@Mork007]

Great video Andy. This is a common issue with Maglites. I have a large 4 D cell variety that had the same thing happen to it. What a job just to remove the old batteries. I know that Duracell now has a new leak proof battery on the market to prevent this sort of thing happening.

[@Tobinindustrial]

Thanks.

[@susanbrown8859]

Thank you so much for posting this. It gave me the confidence to take off the plastic disc which says 'Do Not Remove' and so get inside the torch. One thing to clarify. You say the the small metal tab can be taken out, but not whether it needs to come out. I didn't take it out, then thought I had probably bent it with the force I was using, so took it out part way through. My battery was very stuck, so I sprayed lubricant around it and left it overnight. I then needed to use a hammer and wooden dowel to tap it out next day and my torch is working again!

[@Tobinindustrial]

The pin should come out to prevent it from being damaged. Good call there. That was a great idea to pre-soak the torch. The lubricant has a much better chance loosening the corrosion if left for several hours. Congratulations on getting your flashlight working. Thanks for watching.

[@intimidatorno3ca]

Thank you very much for the way you described this repair. My batteries leaked rather minorly. But when I took it apart the little tab fell off without me even seeing it. If you had not mentioned it I wouldn't have known why my light wasn't working after replacing the batteries. Turned out it was right next to me on my bed but so small I didn't see it come loose. Once I found and replaced it my mini mag fired right up. Saved me from having to buy a new one.

[@Tobinindustrial]

Awesome repair my friend. I am very happy and surprised this video has been so helpful. It is great to have our flashlights operating and not tossed into the garbage. Again, congrats on getting your repair done.

[@1965Karmann]

Thanks for the video. Seeing the teardown made me notice the gounding tab had pinged out of my MiniMaglite while knocking out some stuck batteries. After a quick search around the floor I found it and re-assembled correctly. I used the tip of a smooth round file to clean out the corrosion half way down the tube. New batteries and it's all good again. Cheers

[@Tobinindustrial]

That is an awesome repair you managed to do there. I am so glad the video was helpful to you. I thank you for watching my video. God bless you.

[@rudylaris7478]

03-2021 and this video is still helping people . Thank you Andy!

[@Tobinindustrial]

Thanks for watching.

[@peterwynne7344]

With the help of your video I fixed my torch. The location of the corrosion damage was identical to yours. Thanks very much from the UK.

[@Tobinindustrial]

It is a wonderful feeling to know that I am able to help others in a small way. Thanks for the positive comment.

[@anotherboredgenius283]

just did the same thing... my tail cap was corrosion "welded" to the torch tube, so channel locks and CLP lubricant eventually did the trick - afterwhich, the tail cap and circuit spring were toast. i was able to save the extra bulb and bulb housing in the tail cap 👍. the batteries had also welded themselves to the inside of the tube. again, i used CLP (gun cleaning lube) and let it set in on the whole inside - batteries and all. then I used CHOPSTICKS, to dig at the batteries. i removed the top switch cap, like you did, and then used the chopsticks, as to not damage the switch and components, to gently, but forcibly, push the whole wad back and forth until eventually both batteries came out. luckily, i have a spare tail cap + parts from another aa mini mag, and i will reconstruct from there. great vid!

[@Tobinindustrial]

That was a good save my friend. I am glad you had extra parts to salvage one flashlight out of two. I am not sure if MagLite has parts available for these flashlights. Thanks for the comment and for your explanation of how you got the job done. God bless you.

[@jeffersonianideal]

I've probably owned close to 100 different flashlights in my life. I have never had so much difficulty extracting swollen/leaking batteries from a flashlight as I have with the Mini Mag-Lite. The manufacturer must be aware of this inherent design flaw because so many purchasers have had the same issue. I was able to get the first battery out with a significant amount of time and effort, but without the use of a drill. Even after drilling the second battery it wasn't easy to get out. After all the time and trouble, the Mag-Lite still wouldn't operate even with new batteries installed. This was my first Mag-Lite purchase. It will also be my last. Had I known of this issue beforehand I never would have purchased the device. Ironically, the AA batteries that swelled up were the exact ones (Duracell) included with the Mag-Lite. The more expensive and the more touted the device, the more difficult it is for the product to live up to the marketing hype.

[@Tobinindustrial]

Agreed, it was a design whereby the battery compartment was way to tight and the full metal jacket must have played a role in encouraging the battery leaks to worsen. Thanks fore the comment. I have not purchased another maglite since as well. Probably never will based on that design flaw. They are acutely aware of the issues at maglite but they will ignore it as much as possible.

[@jeffersonianideal]

Thank you for your prompt reply. The best thing that could happen to Mag-Lite is formidable competition. This would encourage Mag-Lite to improve or lag behind. In the meantime, consumers have the ability to exercise their power by voting with their feet and their dollars.

[@Tobinindustrial]

Again, I fully agree. The truth of it all is that there are much better designed flashlights out there and the military grade ones, if you can find an authentic model, are simply awesome.

[@jeffersonianideal]

Thank you once again. Any recommendations?

[@Tobinindustrial]

Bell & Howell has a neat flashlight that I just did a video on with regard to a possible switch repair. The one I bought at Canadian Tire was a clone and not the real deal and it definitely shows. Although the one I have is a neat and durable flashlight, the real military flashlight makes it look sick in the brightness department. Now keep in mind, I am not sure how you will know you got the real military spec flashlight until you actually see it function. Mine at Canadian Tire was also overpriced but I wanted to do an overview and also show how to possibly fix a failed switch on the tail end.

[@alchemie798]

Andy, Excellent video. I was able to disassemble per your instructions. My battery was so stuck, when it finally came out it pressed itself right out of the foil wrapper. Then, the new ones wouldn't fit. Luckily I have a small lathe. I bored out the tube by about .005" and the batteries can now drop back in. I put it back together and voila, it didn't work. What? Turns out there was more corrosion under the spring. After removing the spring and scraping back to bare metal with the same screwdriver you used it now works perfectly. Thanks again. 73/ Allan

[@Tobinindustrial]

+alchemie798 glad the video helped you.

[@susanhyam]

terrific video. I ruined my little metal tab, so I couldn't complete the task....too much corrosion around the end. Thanks very much Andy.

[@Tobinindustrial]

Sorry to hear that. I am not sure if there are aftermarket parts or parts that maglite could provide to repair your flashlight. It might be worth a try to contact them.

[@532bluepeter1]

Thank you very much for posting this. I have a mini maglite with corroded batteries which I have removed. Having cleaned the interior it still does not work and I was nervous about dismantling the top but your demonstration is very clear. I shall do as you did. Fingers crossed and thank you very much.

[@Tobinindustrial]

Good luck... Be patient.

[@davidbryant2872]

Very helpful! Especially the tip about the little tab that will fall out if you don't remove it.

[@Tobinindustrial]

Glad the video was helpful to you David. Thanks for watching.

[@terhazza]

I lost the tab at some point, but I replaced it with aluminum foil and bit of Blue-Tack, works well =)

[@shawndoe2834]

Hey DougHarlow6037 thanks for sharing your 6 day mini mag war. My battery was as stubborn as yours. I'm guessing my mini mag was unused for at least 20yrs. I finished day one of alternate soaking using vinegar and lemon juice. Then I tried tapping the plastic plug down with a small hammer & socket, however, this slightly deformed the plastic plug so I stopped. Then I then turned a long screw into the battery & pulled with plyers but couldn't budge the battery. Then I used a heat gun on the tube & repeated the process by trying to pull the battery out... nothing. Then I figured I'd ruin the plastic plug because that battery was coming out one way or another. I put the mini mag onto a piece of scrap wood and used the flat end of a heavy punch that just fit into the opening. I resumed with the small ball-peen hammer. Nothing. Then I upgraded to my 16oz hammer & basically turned my mini mag into a fine woodworking punch - it punched circular holes all over the wood about 1/4" deep in several different places with each repositioning. Ultimately it took about 30 heroic hits to dislodge the battery. Now I can put this all behind me. Bravo to all the other successful KZbinrs :)

[@Tobinindustrial]

Sounds like yours was super-welded in there over that span of time. Thanks for sharing your story. It was quite the challange you were up against.

[@AndrewDuong77]

I actually had to slam that piece at 3:05 in with a flat head screwdriver to knock the battery out and I cleaned the entire flashlight with lubricant. While I was cleaning, I realized the stuffs in the middle I was trying to clean wasn't the stuffs built-up from leaked batteries, it's actually the steel of the flashlight being ate away by the batteries acid. That piece at 3:05 looks bad on mine since I tried to slam it with a flat head screwdriver several times to get the batteries out. This method really worked and my flashlight is in perfect working conditions again. This video really helped me!

[@mark515a]

I found i could scrape the residue/corrosion off with a flathead screwdriver; then use paper/steel wool on end of a drill bit to polish it.... worked fairly well.

[@gregorypiercesr.794]

Thanks for showing different stages in a reasonable manner and speed!👍👍

[@Tobinindustrial]

Thank you for supporting my YT channel.

[@samwisner]

Thank you. A stiff coarse firearm cleaning brush (toothbrush size) worked well for cleaning the inside of the cylinder.

[@jbirzer]

Thanks. I had tried the drill and screw thing previously, and that didn't work. Yours did. Thanks for saving another mini maglite.

[@Tobinindustrial]

It's great that you salvaged your flashlight. Congratulations on your repair. Thanks for the channel support.

[@GregSr]

Ever since I stopped using Duracell batteries, I've never had any problems removing batteries from my Maglites or Minimags. The Duracells will frequently leak if they are allowed to become weak. Now I prefer Rayovac. Also, the MiniMags tend to flicker regardless of batteries or LED light. Cleaning contacts helps but not for long. The way I solved the flickering issue, was by throwing the MiniMags in the trash.

[@Tobinindustrial]

Very interesting comment. I typically always use Drracell and I have never thought that they may be destined for failure if left for long periods. I have never ever seen an eveready battery leak. It was always duracell that leked and ruined the terminals. Thank you for this awesome information. I think you hit the nail on the head.

[@Jeremy-rg3bg]

Hilarious!

[@JohnTye]

I didn't know I could knock the plastic piece out so didn't try that. Mine luckily came out pretty easy. Thanks for posting the video. You just saved me a perfectly good light that I like.

[@Tobinindustrial]

Happy to be of service.

[@jolson14206]

This was very helpful showing the crucial placement of the small metal tab. Thanks!

[@Tobinindustrial]

I am so happy to have been of some assistance to you Sir. May God bless you

[@pepealonso5884]

I brought my mini maglite back to life. Thank you very much.

[@Tobinindustrial]

Glad to be of assistance to you. My maglite is still working fine after that repair.

[@audreym356]

This worked for me and the Mini Maglite is working again! TBH, I had to watch the part of the video that addresses the part housing the contact point to fully be able to understand the final step. And I was concerned about that part being plastic and how much tapping/force could be used to dislodge the battery without breaking the plastic piece. Fortunately, there was not a lot of corrosion and it only took a few taps to free the battery. Saved myself a few bucks with not having to replace the flashlight and just as important, not tossing away something into the garbage that could be fixed with a wee bit of time and effort to research and do.

[@Tobinindustrial]

Congrats on the repair. It is always a good repair when something stays out of the landfill. I am glad the video I did was helpful to you.

[@p8345]

So glad you posted this. Mine has been stuck for 2 years, I didn't want to drill it for fear of ruining it. I'm glad you suggested wd40. I'm going to use that and hopefully it works.

[@Tobinindustrial]

Let me know how it works out. All the best and God bless.

[@kimbenbow1358]

Worked like a Charm! Thank you!

[@Tobinindustrial]

Congratulations on repairing your flashlight. Thanks for the channel support.

[@martyharless5097]

I have found the best way to prevent this from happening in my experience is to use Eveready Energizer batteries. I have never had an Energizer battery leak, not one time ever. I have a bin of used batteries and even after years of being in the bin the Energizer batteries just do not leak. In contrast the Duracell batteries piss all over themselves. Duracell batteries have constantly leaked on me and I use my flashlights everyday at work. I will not put a Duracell in anything I own. I also tried ACDelco batteries and that resulted in a ruined flashlight that I had just purchased. I had many of them leak in the package and many of them lose voltage in the package to the point where they are not usable. All of this while still having eight years left on the expiration date.

[@Tobinindustrial]

I fully agree. I have a flashlight with eveready batteries and it always works and when stored it has never leaked. You are on to something my friend. Thanks for your comment and for watching my video. God bless.

[@c.w.winger221]

This is my experience with energizer and Duracell. I've lost some great flashlights due to leakage. meanwhile I have two lights that have had energizers in them since about 1991, both work, no corrosion. kept in horrible environments.

[@Tobinindustrial]

@@c.w.winger221 Agreed. Duracell is the culprit I believe as well

[@whatfreedom7]

I fixed mine by throwing it in the garbage. Compared to modern flashlights my older maglite led is way behind in performance anyway. Today’s Penlights are more effective by a long shot.

[@Tobinindustrial]

Agreed... There are many better flashlights out there

[@KutWrite]

You have a point. Sadly, mine is a memento of a former job. So, I'm gonna try and fix it. A copper clip fell out though & I have little hope of figuring out where it goes. This Maglite is probably pre-divorce of the inventor.

[@johnscibelli7580]

After wasting more time on this piece of garbage I followed your suggestion. I'm much happier now. Thanks.

[@jonesba2004]

whatfreedom7 I fixed mine the same way.

[@mikeheckman4995]

I see that I'm not alone here. Tossed it! Bought a SureFire.

[@rreneflores753]

Than you so much, it was hard find a good video about, i find all what i need in this one. 👍👍👍 I don't speak English. Soy mexicano

[@Tobinindustrial]

You are welcome!

[@tiozoso]

If your battery is stuck, find a drill bit that'll stick all the way down and use the drill on the bottom of the battery inside the light. Then use a screw and drill that in where you drilled the hole, then try to pull it out. You may be lucky enough to pull the battery out with the drill bit which is how I just got mine out!

[@Tobinindustrial]

I tried that but mine was stuck really good. It can work though and it is a good idea you mentioned. Thank you for watching my channel and God bless you.

[@tiozoso]

@@Tobinindustrial Yeah I see yours is the older style. Mine which is LED wouldn't work that way, otherwise I would've tried it. But of course I'll be sure to come back and try this if I ever have this happen to one of those if need be. :)

[@princessheart82]

Thanks for your video! Saved my mini mag, and it took less than a minute.

[@Tobinindustrial]

Thanks for watching my video.

[@santoshkiran_u]

Thanks a TON I was stuck with this problem for 4 years. The drilling didn't work for me too, it just messed with the rear screw and I have a hard time putting back the end cap.

[@Tobinindustrial]

You are welcome.

[@BennettBurke]

Thanks. This helped my see how easy it is to take out the bulb and the plastic bulb holder (ha, that says "do not remove"). Then I got some WD40 and a small dowel and punched the battery right out from the bulb end. Good as new.

[@Tobinindustrial]

Congratulations on your repair of the flashlight. Hopefully it will never happen again.

[@DonEllis]

Rather than pushing first, I soaked the unit (after removing lamp, reflector, & switch) in seltzer water (thanks to SodaStream for unlimited cheap seltzer!). Waited about an hour or so, then was able to push the battery out with an awl through one of the holes in the plastic part. Before soaking, the battery was thoroughly stuck. In contrast with WD40, the seltzer was less disruptive and easier to control (and cheaper). Yes, I've seen some very interesting torches in recent months, especially one that was on sale ($30) at Ace Hardware with rubber casing, magnetic base, and side flood. Then I found a much smaller miniature similar design at Home Depot (Frogleggs -- same features, but massively slimmed down, uses 2x AAA) for $5. I don't need super sturdy, especially if it's easy/cheap to replace. Still love my Maglite. I've replaced the halogen bulb with the newer single LED, so it can still focus. Earlier LED upgrades had 3 LEDs and don't focus. Switch in base came with LED upgrade.

[@Tobinindustrial]

Very interesting. I think I purchased a rubber cased flashlight with a flood and tip light for the motorcycle. It is LED and works very well and has that magnetic ability. I bought it at Home Hardware. It was only about $12.00.

[@majesticmalfeasance]

I was glad to learn that the plastic piece in the top would move down with the battery. I used the suggested method but the battery became stuck around the middle and no amount of tapping seems to move it anymore. Maybe the drilling method should be the next step. Unfortunately, somewhere along the line, the little metal contact that you pulled out with tweezers just fell out and disappeared, so the maglite won't work even if I do finally get the battery out.

[@Tobinindustrial]

Too bad about the little metal piece but you can contact Maglite and see if they can send you another. As for the battery, can you try moving the battery back the opposite way and use a loosening agent and then work it back out again. Keep pushing it back and forth and it might come loose. As for drilling, it may relieve some strain against the wall if you drill with a larger bit but you risk damaging the wall of the flashlight housing. Please keep me in the loop as to your progress or of any other things you might be able to try.

[@mouseanalyse]

Worked for me! Just saved my Mini Maglite! Thank you sir!

[@Tobinindustrial]

Happy to be helpful anytime. You are the problem solver though. You saved your flashlight so congratulations to you and all who managed to do so. God bless.

[@TRex-NP]

thanks for this. almost threw out a perfectly good maglite. going to use NiMH batteries in it from now on. i actually used a sledge hammer with another battery going from the top. made it really easy. cleaned out the rest with white vinegar.

[@Tobinindustrial]

Thanks

[@mielflorea]

Thank you sir. your video saved my maglite, too.

[@KennyFishbone]

CAREFUL tapping the bottom of the housing...it'll crush the threads. Good tutorial!

[@Tobinindustrial]

Good tip!

[@jinendrajain6972]

Thanks a lot, sir! Your tutorial helped me save three torches. Very useful 👍👍👍😊

[@Tobinindustrial]

Wow, that is a personal record for this video. I know the feeling of salvaging one flashlight so you must be elated. Congratulations on getting the job done and saving the torches. You deserve all the credit.

[@ethboy85]

Thanks. Worked for me. I used my gun cleaning kit to get the corrosion out.

[@Tobinindustrial]

+eth Yes, that would be an exceptional way to get the corrosion out. I thought of that but I didn't have a gun cleaning kit. Fantastic idea though. Thanks for your comment

[@randykeeling5508]

Hi, Thanks for this video. Got an old one last night for 60¢ at a thrift sale. Battery was corroded stuck inside, I took my good one apart to look at it and the switch part fell out the battery side. When I tried putting it all together it didn't work. I finally found your video and at 3:05 - 4:08 it showed that little metal piece that goes on the battery side of the switch. It was missing on my, So went back out to shop and found that little piece. Works fine! Still working to get my corroded battery out now though. I may have wasted 60¢. Thanks again for good clear video! ;-) *Sadly though now I realize my 60¢ is missing that same little pin. :-(

[@Tobinindustrial]

I think that if you contacted Maglite they may be able to source that part for you. You never know. Good luck with the repair. I hope you can get it all sorted out and have two flashlights working. that would be awesome. Thanks for watching my video and I am so glad it was of some help to you.

[@randykeeling5508]

Andy Tobin Old one is working fine. The one from the thrift store is proving to be a formidable opponent as to getting the second battery out. It's now soaking with coke again for the second time. It's really welded itself in there. I've wasted way more time on it than it's worth. At this time if i get it all out, i will have to replace the whole switch assembly now. 😁

[@RedWhineman]

Thank you! You helped me save my 40yo mini mag!

[@Tobinindustrial]

Glad you got it fixed. Merry Christmas.

[@mdf58]

This technique works for the AAA version, also. My upper battery wasn't solidly stuck, just enough leakage to not let it slide out. If yours is stuck solidly, be very careful to use a correctly-sized tool to push the battery and upper lamp holder down through the body.

[@Tobinindustrial]

Thanks for your comment and information. It is amazing how many flashlights have failed this way.

[@jamesbarnett8318]

I just sprayed WD-40 down it. It worked! I also have the LED version, and I tried to remove the bulb compartment first. I think I bent something.

[@Tobinindustrial]

Sometimes the corrosion is not so bad but when the batteries swell too much they really get jammed in there good. I am happy to hear that WD40 did the trick for you

[@Demonbfg]

I have the LED version as well and the WD-40 worked,Thanks.

[@Tobinindustrial]

Good job my friend. Congrats on the salvage of a good flashlight. The LED version is really great on batteries.

[@wmsammons]

Much simpler to tap out s. Drilling method!! Another post showed where you can send the mag light back in under an extended warranty depending on the battery that corroded something else to check out cheers to all

[@Tobinindustrial]

Thanks.

[@dude...are-you-sure]

For your future reference in order to clean the battery acid. You can mix a solution of water and baking soda and that will eat up the acid and clean the housing. You can use the solutiom instead of using wd40 as wd40 doesn't dissolve the acids and this solution of water and baking soda will.

[@Tobinindustrial]

Thank you so much for this information. Baking soda will certainly neutralize the acid. This is a great idea and that is usually something that is found around the home.

[@CaalamusTube]

Far more reasonable method than drilling holes in a battery or turning your Mag into a pressure cooker! 'preciate ya :]

[@Tobinindustrial]

Thanks for the view and comment Caalamus.

[@billcalkins2961]

Mine was the led model where the led only comes out the rear side.I almost threw mine away. I used drill into the battery from the backside, then an Easy out- that's better than a screw. First I spray in some wd-40 and let it sink in a bit. Battery pulled right out after everything else I tried failed. The LED head wouldn't fall out so I used a screwdriver with a removable bit as not to damage the led bulb. Push it out the back. I then ran a ball of emery paper through it to clean it good, put more wd-40 in and added new batteries. Good as new

[@Tobinindustrial]

Awesome idea with the easy out. Sadly, I don't own one. Some great ideas on getting the batteries out my friend. Merry Christmas

[@LifeOfPabs]

i've had this flashlight since i was about 8 years old or so this is the first time this has happened haha popping out the top was the first thing i did but wanted to make sure i wasnt going to damage something before i continued thanks for the video!!

[@Tobinindustrial]

Thanks for watching my video. I am glad I was able to help. As a side note, was it Duracell batteries that were stuck in your flashlight?

[@LifeOfPabs]

@@Tobinindustrial I used some eneloop rechargeables

[@Tobinindustrial]

@@LifeOfPabs Did the eneloop rechargeables the ones you had stuck in the flashlight?

[@LifeOfPabs]

@@Tobinindustrial so I finally got the second battery out just today. Used some CRL to help and a metal rod from a hammer I made in metal shop in high school 😂 so it turns out the battery that went sour was actually a Rayovac. There was a Rayovac and an eneloop which is probably why it went bad in the first place

[@Tobinindustrial]

@@LifeOfPabs yeah, mixing batteries is not a good idea

[@Spiritgumm]

I had to remove corroded batteries a month ago, but when I reassembled with connector pin as shown, the light stayed on. It had to lay over the tube top, not under it, for the light to go off. Anyway, had corroded batteries again (why???), and when I redid it, the connector pin broke. I tried substituting some thin wire, but that broke when I screwed down the head. Wondering what I could use to replace the pin, or if I should buy a new light.

[@Tobinindustrial]

Maglite does not respond to my emails. I am not sure where to get parts for this flashlight. I don't use Duracell batteries in my flashlight and so far, I have not had any leakage issues since.

[@mardemolidor]

Thank you very much I bought my maglite semi new lantern in the garage sale was mounted wrong and you helped me from the heart I'm super glad

[@Tobinindustrial]

Congrats on getting your maglite working. Thanks for watching my video as well. I appreciate the support. God bless you.

[@aytugaksu1625]

Thank you Sir! Your description was most helpful!

[@Tobinindustrial]

Happy to be helpful Sir. Thank you for watching my video. God bless you.

[@AdamFink83]

Thank you sir. your video saved my maglite.

[@mikeantisdel272]

The best way is throw the SOB away and buy a new one. Then start throwing the batteries after so much use, like the lite starts to dim indicating the batteries are getting weak. Never leave the light sit with batteries in it.

[@Tobinindustrial]

Agreed. Sitting batteries are the ones that will eventually leak.

[@ronaldschild157]

Thanks! I was wary of removing the black plastic part that the bulb leads plug into. It is inscribed "Do Not Remove" but glad you are showing us how to indeed remove it. I really like the flashlights and the quality never wavers, so it is a shame thinking you have to discard one if the batteries have leaked. Your efforts give hope to those of us experiencing leaking batteries in the MagLite®.

[@Tobinindustrial]

I really liked my flashlight as well and so I made a serious effort to salvage it. Thank you so much for watching my video and I am glad it was beneficial to you. God bless you.

[@jami7772]

Really good video. Detailed and close up ! thanks

[@Tobinindustrial]

Thanks.

[@charleseverett7760]

Great video! You saved my flashlight.

[@Tobinindustrial]

Glad I could be of some help. Happy flashlighting.

[@Tobinindustrial]

Response to Tee Bee: Vibration (Tapping) the flashlight while it is wrapped in cloth to stop damage may work the threads free. A loosening spray may also be helpful. Also, using heat can help loosen the threads up. In every event, be careful not to damage the flashlight. A rubber mallet tapping the threads while the unit is covered in a thick cloth will reduce the chances of damage. You could also use adjustable wrenches to grip the light in separate directions and try and loosen the thread. In all instances, cover the flashlight with material to prevent scratching or damage. Do not use too much pressure as the tube of aluminium will be crushed me towards the batteries. So,hammering, loosening oil and moderate heat might help.

[@Tobinindustrial]

I am glad it was helpful to you.

[@sa3270]

I have two maglites like this, an older one with an incandescent bulb and a newer one with an LED bulb. They both have batteries stuck in them. The bulb appears to be damaged and burnt out in the older one. In the LED flashlight, I was able to get the plastic sheathing out from between the bulb assembly and the outer case, but still could not remove bulb assembly to expose the battery. So I think I'll just toss both of them and get a new flashlight.

[@Tobinindustrial]

Yes, sometimes they corrode so badly that they are beyond fixing. I hope you have better luck with your new flashlight.

[@victoriaking3966]

Absolutely brilliant - thank you so much for sharing.

[@Tobinindustrial]

You are so welcome. Thank you for supporting my KZbin channel.

[@SpectreOZ]

Tut... tut... tut... leaving primary cells in any device for prolonged periods is "Bad Ju Ju" but definitely glad you were able to reclaim the Mini Maglite, I'm rather fond of flashlights in general :D BTW you might want to clean your bulb with denatured alcohol after handling it like that... our natural skin excretions effect the longevity of incandescent bulbs.

[@Tobinindustrial]

+SpectreOZ Thanks for the heads up on the bulb cleaning. And yeah, the flashlight sits in a case and is seldom used. I really should pull the batteries but it is so handy when it is just grab and ready. Thanks for the comment

[@SpectreOZ]

Andy Tobin No worries Andy and thanks for the entertaining story/tutorial... where was the Qual-i-TEA?

[@Tobinindustrial]

Guilty as charged.I must make sure the mug of tea is visible.

[@UTubafy]

Thank you, Mr Tobin. Your advice really helped me.

[@Tobinindustrial]

+UTubafy You are most welcome

[@dangalea8289]

Worked a treat!! Thank you.

[@Tobinindustrial]

I am happy that you got your flashlight working again. God bless you.

[@StevenKeery]

I have three or four maglite torches, the batteries have leaked and frozen up inside of them, so much that I can't even unscrew the end cap. I'm trying to release them from the bulb end by spraying down the tube with WD40, to see if this helps. It has certainly put me off buying any more Duracell batteries, as that is the brand that has caused the problem.

[@Tobinindustrial]

You might want to soak the flashlight overnight (or longer). Also, a bit of heat may help but be careful as they are aluminium for the most Vibration (tapping) can help break stubborn and locked threads, I hope you have the patience and willingness to keep trying. All the best with it. Please keep me posted.

[@lrhnyc]

I found this to be incomprehensible. How does he get the batteries out ? All the instructions about disassembling and the small metal tab (which apparently gets removed and later replaced, although we never see that happen) but how do you get the batteries out ???

[@Tobinindustrial]

The intent of the video is to stess tapping/ vibration to loosen the batteries and spray to loosen the batteries. Many people have found this a useful video and it helped them salvage their flashlight. I am sorry that the video was not helpful to you. My video was regretfully done after the fact and so this is only a demonstration as to how I managd to do it. The rest is just good luck and using common sense techniques to try and salvage your flashlight without destroying it altogether.

[@Demiglitch]

Thanks for the help. you have a great accent

[@Tobinindustrial]

Glad to help. God bless you. I am from Newfoundland, Canada.

[@prosnick]

Thanks so much! This was exactly what I was looking for!!!

[@Tobinindustrial]

They are pretty expensive lights so I am glad you got it fixed

[@KailasaIshaya]

I think I missed something.... How do you get the light assembly out IF you have 2 stuck/frozen batteries in the flashlight tube?!?!

[@Tobinindustrial]

It depends on whether or not the end that holds the light assembly releases. Both ends released but the batteries were swollen and stuck.

[@stockholm1752]

Take off the head/bulb and all that, then rinse the barrel under hot water for a few minutes. It works.

[@Tobinindustrial]

Interesting, thank you for that idea. I will try that if my light ever gets stuck batteries again.

[@stockholm1752]

Best thing is to not leave batteries inside whatever thing for too long if you're not using it regularly, but you know that. This happened too me once, and hot water solved the problem. Cheers.

[@Tobinindustrial]

Agreed, an ounce of prevention is worth a pound of cure. Thanks for chiming in with your idea and for commenting. God bless you

[@jerrymontalbano3222]

Well, you mentioned how to get the little object (small plastic battery end), but didn't say anything about getting the corroded batteries out. Hamming with a screwdriver can smash the plastic insert into pieces (even if gently as it does take an effort to try and get the plastic out).

[@Tobinindustrial]

Yup, depending on the situation, there is risk of damage. That's why I warn everyone really take their time, soak it, tap the outer circumference, etc. There are risks to doing damage in any repair. Many people got their batteries out. Read the comments. Each battery freeze is somewhat different from everybody else. The attempt to repair with some foresight is the way to go. Some people just toss the flashlight in the garbage. Nothing wagered - nothing gained. Thanks for your comment and for pointing out the possibility of the ever lurking unknowns of doing repairs.

[@dougharlow6037]

I have a mini maglite - 2 AA 1st the insides look new, I see NO corrosion, but batteries are REALLY STUCK. I've tried water and baking soda, 2-days I've tried WD40, 2-days I've tried vinegar, 2-days I tried pounding them out ruining the switch on top and the batteries just will not budge????????

[@Tobinindustrial]

That sounds like a real big issue my friend. I would conmtinue tapping the outside if the flashlight to try and break the batteries free. Be ultra careful not to crush the cylindrical shape of the flashlight case and do not damage the finish. You have really put a lot of effort into it by now. Multiple taps may loosen something but it sounds like your batteries ar really swollen up big time.

[@shawndoe2834]

Hey Doug I think I have a battery as stubborn as yours. I just finished day one of alternate soaking with vinegar and lemon juice. I tried tapping the plastic piece down with a small socket but now its slightly deformed so I stopped. I'm close to tapping out but I might try a heat gun on it tomorrow as someone mentioned heating it up.

[@irenesilbert402]

We have a cart/horse problem here. I am trying to remove the bulb socket so that I can drift the stuck battery out. I can't drift the bulb socket out with a stuck battery in the way. I am still wondering how to remove corroded and stuck batteries.

[@Tobinindustrial]

I think your best bet is to soak the flashlight in a loosening agent like WD40 perhaps. After soaking, the battery does not come free. gently tap the outside of the flashlight housing without damaging it. Tap it with a rubber mallet multiple times to try and loosen that battery. Do not tap too hard to cause deformation of the flashlight tube as there is very little clearance between the tube and the battery in the best of times. If this does not work. The only other option is to try and drill out the center of that battery and pry it out. This is a procedure and needs to be done carefully to prevent further damage to the flashlight. I honestly think that soaking the flashlight and tapping (vibrating) is the best option. Patience is the key. eventually, the battery should loosen bit by bit with soaking and tapping. I wish you luck with it.

[@brucevilla7490]

This is a very common failing of maglite flashlights and why I don't use this brand anymore. Buy a Snap-On flashlight. I have used mine for many years, no problems.

[@Tobinindustrial]

Thanks

[@eskimo5973]

the days of rating stars are nostalgic

[@Tobinindustrial]

Hello.

[@pnwprydenorthwest9020]

Not sure if I'm missing something but you don't actually show how the light housing cane be removed from the front end of the flashlight. The back end is plugged by a stuck battery.

[@Tobinindustrial]

In that regard you just have to pre-soak the whole flashlight and when it comes to removing the stuck batteries care needs to be taken to not damage that piece of the flashlight. I am not sure if the pin can be removed so that it won't be damaged. Sadly, I had done the whole procedure and did not video the step by step. It has been a long time now and I don't recall much of what steps I did take but I do know I salvaged the flashlight and all the integral parts were not damaged or lost.

[@scottiron6444]

Thanks man!

[@Tobinindustrial]

I am glad it was helpful to you.

[@glauciogv5225]

Perfect video, congratulations !

[@Tobinindustrial]

Thanks so much. God bless you.

[@kraigcochran9995]

Thanks i found an old mini mag in a box today and couldn't figure out why it wouldn't work, the little ground tab is missing! Don't know how or when but I've probably had this light for 25 years so hard to tell.

[@Tobinindustrial]

Interesting story and others have had that tab missing as well. I am guessing that the batteries may have shorted out and burnt up that little thin ground clip (Just a guess)... Perhaps if you got a hold of Maglite, they might be able to send you the part in question. Also, if you knew what it looked like you might be able to make a replacement part yourself somehow. Good luck. Keep me posted on your progress.

[@lisacolbert5987]

I helpful Canadian guy ! Thanks. I've got at least 5 maglites with leaked batteries in them. If there's a power outage I coulda maybe rubbed them together and made a campfire ?

[@Tobinindustrial]

Thanks for your positive comment and thanks for watching and supporting my channel.

[@lisacolbert5987]

Andy Tobin you're welcome!

[@CB-RADIO-UK]

Good video Andy. I would have prob gone in too heavy handed and damaged the flashlight.

[@Tobinindustrial]

Thanks.

[@HigesoriHanzo]

Worked perfectly. Thanks, man!

[@Tobinindustrial]

I am happy the video was helpful to you.

[@miguemoncayo]

This really worked. Thanks bro!

[@Tobinindustrial]

Glad it worked for you.

[@TheWeirdSide1]

What does this have to do with removing batteries? If batteries are stuck, then "gently tapping" on bulb socket is going to do nothing. I just hit mine as hard as I could using your technique (after giving up and just before tossing the whole thing in trash). All it does is crush plastic socket into first stuck battery. Your batteries must have not been very stuck..A simple tap on hard surface would have sufficed.

[@Tobinindustrial]

It's all about the courage to set out and try rather than toss it.

[@LouiesLog]

Just what I needed thank you :)

[@Tobinindustrial]

I am glad you got your flashlight back to functional. Thanks for watching my video. God bless!

[@Dropzzzone]

I broke my outer case 'pin' battery connection doing it the same way - wish I'd seen your video first....

[@Tobinindustrial]

+Nick Siddall That ius too bad. So sorry to hear that as they are nice and reliable flashlights

[@cmck472]

Wear she protection! I ended up in A&E trying to leave a battery out of a maglite, some of the battery shot into my eye. It stung like hell, and apparently slimline is more damaging than acid. They spent several hours washing my eye out and I had blurred vision for 3-4 days.

[@Tobinindustrial]

Always wear eye protection when dealing with batteries. There is a warning on every battery package. You are absolutely right.

[@PatriotMarine]

...if the battery is really stuck in there, you'll damage 'plastic" maybe putting Coke in there first will loosen corrosion? Mine I can't remove battery cover.

[@Tobinindustrial]

Tap the threaded area of the battery cover gently with a small rubber mallet. Remember, very gently! Tap it 100's of times while turning but do not danage or squat the metal. There is corrosion in amongst the threads and if you vibrate the threads with miultiple light taps, it may work. It is the same principle that an "impact" air gun does to loosen stubborn bolts. Also, you can put the flashlight in a vise but wrap it in rubber or cloth where you clamp it and do not squat the metal. Then take a vice grip with cloth in the jaws and gently clamp it on the battery cap nd twist it counter clockwise gently and see if that might help work the threads loose. Be very patient and you will get the cap off if you follow these instructions. REMEMBER.... easy does it. 100 light taps instead of three hard smacks and hopefully nothing will get broken or damaged.

[@teebee1204]

Unfortunately the first step stopped me. The (battery) end seems stuck on and I can't twist it off.

[@terhazza]

Soaking it with water and CRC/WD40 helps. One can also try to press a long screw inside the battery and pull it out.

[@philsmith2222]

What is that contact piece and the two pin plastic cap piece called. Can you get replacements anywhere?

[@Tobinindustrial]

I'd say contact Maglite thru online and see if they'd send some complimentary parts to you. Have your model of light ready to pass along to them. The website is: maglite.com/support/contact

[@tommyamaro]

How in the world does removing the contact piece help remove the battery blocking it from being removed!??'

[@johnwhiteley7846]

Tommy Amaro will

[@mouseanalyse]

Precaution. Because you don’t want to damage this piece at all! Plastic was damaged from hitting a bit with a hammer (was stuck solid). So yes, this makes perfect sense to take it off.

[@LaVieBoheme1102]

@@mouseanalyse but there's a battery stuck, how the hell is the contact piece able to fall through the bottom??

[@mark515a]

@@LaVieBoheme1102 you can use tweezers to remove from top, carefully, as you have to clear the lip. really had to slam down on top with hammer and rod to dislodge, but it's working now.....

[@frofrow]

mine would not come out at all while tapping the flashlight on a hard surface. i used some coke a cola and put a little bit inside the casing and let is sit over night. the next morning, they came right out!

[@Tobinindustrial]

Awesome idea. Thanks for watching and congratulations on the repair.

[@rickenglish4091]

Kenner Bowers

[@frofrow]

yes?

[@kurtkenehan8017]

do you know if vinegar would work?

[@Tobinindustrial]

It just might work. I think it would.

[@ericksda84]

Thanks. It was a great help.

[@Tobinindustrial]

+ericksda84 Happy to be helpful Sir. You are most welcome.

[@Thevinylhouse]

Off topic, What kind of rig is that? Looks like a Yaesu, but cant figure out what model

[@Tobinindustrial]

That is a Yaesu FRG 7700 shortwave radio. Thanks for watching and for your comment.

[@ppsuksiri4245]

I tried tapping the thing with the metal part out but the battery on the other end was to stuck

[@EyeGlue]

What you did NOT cover, as far as I could see, IS how to ensure that the interior of the aluminum barrel is cleaned of "chalky" corrosion build up and residue that can otherwise impede or obstruct the fresh batteries (from dropping into place) when inserted into the barrel. Having looked at other "how to" videos, the agents for cleaning up corrosive residue are either baking powder or vinegar or isopropyl solution......I realize WD40 is a lubricant, but I don't believe that it will attack and remove corrosive residue from batteries. My flashlight (a Dorcy) has residue inside the aluminum barrel that will not come off the inside of the barrel and thus the flashlight is basically f**ked......:=)

[@Tobinindustrial]

Very true. Luckily, mine cleaned up well. I have never had that "Chalky" corrosion as bad as you had it. It always cleaned up well for me so I guess I just placed a little emphasis on a good cleaning. I am unable to help you in your situation because I have never experienced that bad of a situation with corrosion. Thanks for your post

[@taomahNEGEV]

No way I'll ever buy a Maglight again.

[@Tobinindustrial]

I understand your frustration. Maglite has no customer support with this issue.

[@travisluraas1620]

Thanks sir, worked great!

[@Tobinindustrial]

Thanks for watching. I am happy you got your flashlight fixed

[@bryanbatton01]

What did you use to remove corrosion

[@Tobinindustrial]

I used WD40 and a tooth brush. I suspect vinegar would work. You could use any loosening spray really.

[@bryanbatton01]

@@Tobinindustrial thank you sir!