I am recreating vital steps with graphics. I made a graphic rather than a photo because I was very uncertain about how this project would turn out. See the next steps for its removal. Shine away the darkness and keep going strong with MagLite OEM factory parts.This is a graphic I did of the Switch Sub Assembly after it has been removed from inside the flashlight's barrel. The MagLite replacement Switch Seal fits any MagLite MagCharger flashlight. Replace those missing or worn out parts and keep your MagLite flashlight running as good-as-new.When you are finished, the total cost will be almost as much as a new flashlight. Be aware you will need a couple of special tools, too. It is possible to order the switch or the Switch Sub Assembly at this web site. I left most of it in the neutral tones rendered in Google Sketch Up for clarity. The Switch Sub Assembly is made of black plastic. Although two are shown, there are actually four.There is a corresponding contact point directly across the opening for the switch, which is below the spring under the bulb socket. Notice the contact for the battery tip that runs through the bottom of the Switch Sub Assembly. You will need to remove the Switch Sub Assembly from the Maglite, but more about that later. As the head of the flashlight is turned, the angle at which the reflector is cut allows the bulb socket to move so the beam of light can be focused from wide angle to a narrow spot. Part of the reflector rides on the brass follower. The bulb socket is spring loaded and can move up and down.
Then you can slide the Switch Sub Assembly out of the lamp end of the flashlight barrel. Next you use a small hex wrench to loosen a set screw deep inside the switch that digs into the inner surface of the barrel. Then you pry the rubber switch seal (# 15 in the exploded diagram from the web site in step 1) from the barrel of the flashlight. Featuring Replace those missing or worn out parts and keep your MagLite flashlight running as good-as-new The MagLite replacement Switch Seal fits any.According to the web site linked in step 1, you use a special tool to unscrew a retaining ring. I went to work at removing the large snap ring. What I did is a bit different. At this point I believed there might be a shoulder toward the rear end of the barrel that would keep me from sliding the Switch Sub Assembly out of the rear end, but that proved to be false. LED Flashlights that haveD or DL in the serial, and LED PRO SERIES. I drilled a hole into the plastic Switch Sub Assembly between the ends of the snap ring.The switch seal is designed for most Maglite Flashlights that take the D Cell battery.Incandescent Flashlights that haveD in the serial. I removed the flashlight's bulb. It unscrews just like the rear end cap. I removed the head of the flashlight with the reflector and lens. I drilled through the flashlight case between the hole for the switch and the "O" ring seal in a place that would be hidden by the flashlight head when screwed back onto the flashlight. I cut the wire at about 1 1/2 to 2 inches in length. I tinned the end of a piece of stranded wire about 20 gauge with solder and then heated the solder on the follower to make a good solder joint with the wire. See all 7 brand new listings.Find many great new & used options and get the best deals for Maglite Mag LED Charger V2 Flashlight Switch Seal Replacement 118-000-200 at the best online.While the Switch Sub Assembly was still outside the flashlight barrel I used my electric solder gun to place a little solder on the brass follower. Maglite Switch Seal Replacement Driver To TightenIn the meanwhile, it is a good time to cut the excess from the screw on the outside of the barrel and file it smooth.I chose option #2 for my flashlight. A replacement for the switch must be handled first. With my soldering gun I added a dab of solder to the 6-32 screw head, but it is not yet time to solder the other end of the wire to the 6-32 screw's head. I used an offset screwdriver to tighten it as much as possible. I started the screw with a needle nose plier. Maglite Switch Seal Replacement Install It InsideThis made a very good resting place for my switch. Although my graphics do not show this detail, there is a shoulder inside the switch opening on one side. I had to grind the outside diameter a little to make it fit into the round switch opening. I found a flat washer with an inner hole the same diameter as the threaded body. This switch has a nut and a threaded body. It is small enough that I could install it inside the switch opening in the Switch Sub Assembly and slide the entire package into the rear end of the flashlight. Sometimes I find I have totally missed someone’s comment. I am not sure if I saw your comment when you posted or not. Note: the red switch button pries off of the rest of the switch fairly easily.Steve, I am sorry I have delayed this long. I touched them to an abrasive wheel and rounded them off until the whole assembly would slide into the flashlight barrel. The square corners of the red switch button and its black housing were in the way when I first tried to slide the Switch Sub Assembly back into the flashlight, even when fully pressed down. I soldered two pieces of stranded 20 gauge wire to the contact points and then soldered the other ends to the switch. I use the light more since my fix than I did before with the factory switch that finally quit on me. I actually like it better than the original factory switch. The Radio Shack switch I improvised for my Maglite is still working just fine. Last night I stumbled onto what I sent to you. Tamil grade 1 cbse worksheetsFrom 1972 to 1974 we lived south of Milford, Ohio. He was happy.) I am glad you can still use the Maglite information, despite my slowness. Since, someone with a beam saw, that is, an electric handsaw or circular saw with a blade 10 or 12 inches in diameter saw it and was able to make a blade for his saw after the maker had discontinued them. I did that for a friend so his 1950s radial arm saw was still functional. (I posted an Instructable several years ago on fitting a 9 inch saw blade with a 5/8 inch arbor hole to an arbor 1 1/4 inch in diameter. Unfortunately, too many times I have looked for things and found I would be the one who would need to find the solution to my problem and post it for others. I even rode my bicycle from the house on Romohr Road to Greenhills and to Cheviot (Harrison and Boudinot).
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