Maglite 4D repair questions ....

[AimlessWanderer]

Any Maglite wizzo's out there?

My neighbour collared me to see if I could help him resurrect his 4D cell maglight which was heavily corroded. Tail cap and body threads have been cleaned up, and also cleaned the tailcap spring so there should not be any contact issues at the arse end. New bulb and batteries put in but still no life. I want to try and remove the switch/bulb housing assembly to check for corrosion. How the smurf do I get it out? Is there anything else I should be checking for? I've shone a torch down the barrel, and the contact on the underside of the assembly seems clean enough, but I'd like to remove it if possible to have a better look/poke 

Any thoughts would be welcome, as believe it or not I've never owned a Maglite

[dks]

I assume you have tried these but:
Use an ohmmeter (from e.g.  a multimeter) to see if there is proper contact through the tailcap. Use the switch too, to see if it works (when off/broken circuit the resistance should be infinite)

Also connect a battery directly to the head (lightbulb) to check that it works.
I also sometimes use some contact lubricant spray (not the standard cleaner) which helps re-establish contact in older switches.

These are general points, as I am not a Maglite expert of any sort.

[Millhouse]

Maglite D Cell Switch Disassembly P 1


If no luck, and he doesn't need the maglite for  purposes, maybe time to consider something smaller, that will be more powerful.

[AimlessWanderer]

Cheers chaps!  We got the switch assembly out and it was knackered - totally!!! Looks like there's been some battery leakage in there which has been eating away at stuff. Time to see if we can track down a replacement switch unit.

EDIT: Replacement unit and tail soring ordered

Thanks again fellers