Adapter for Mini Maglite and repair

I am not going to show you how to replace batteries. Instead, we will go straight to the point:

How to disassemble the switch and do a few quick tests with an multimeter (ohmmeter) to verify the flashlight does work.

First, you have to unscrew and remove the tail cap and the batteries. Then remove the head and pull the lamp (it's not a diode in this model).

Insert the tool (alu rod + orange adapter) into the bottom of the barrel. Rotate the tool until the 2 pins enter the 2 holes in the bottom of the insulator.

Place the tool and the barrel on a flat surface and push down on the barrel. The top insulator should move upwards and separate from the bottom insulator.

My switch had the side contact corroded. I used some fine emery paper to clean it. You can use a contact cleaner as well.

Put everything back together.

If the flashlight still doesn't work, check the lamp with an ohmmeter. It should show a very small resistance. Check the resistance between the tail cap spring and the aluminium thread. It must show continuity. Check the battery contact (round) on the switch. It can be corroded. Clean it with a contact cleaner or a fine emery paper.

Good luck with your repair.

Drawing if you want to 3D print the adapter (PLA):