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.

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

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.

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.

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.

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

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!

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

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.

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

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!

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

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.

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

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!

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

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

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.

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

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.

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 KZfaqrs :)

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

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.

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

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.

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.

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. :-(

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

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

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.

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.

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

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

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.

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.

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!!

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.

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.

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

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.

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

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.

Worked like a Charm! Thank you!

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

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®.

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.

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

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

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

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

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!

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.

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.

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.

Thank you Sir! Your description was most helpful!

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.

Thanks for the help. you have a great accent

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.

Great video! You saved my flashlight.

Thank you sir. your video saved my maglite.

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 ???

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.

Really good video. Detailed and close up ! thanks

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.

Worked a treat!! Thank you.

Absolutely brilliant - thank you so much for sharing.

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).

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.

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

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

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

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.

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.

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.

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.

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

the days of rating stars are nostalgic

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.

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

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????????

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

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

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!

This won't work on the led pro the led has to come out from the back .I cut a screw driver wide cut across the bottom of the battery with a small bur and dremel tool then turn the battery . If the screw driver only turns the cap and cap only then unfold the metal that holds the cap on . once you remove the cap use a smaller screw and pry between the battery and flash light . sense the cap is gone the battery can be pried into the middle where the cap was . Go all the way around . top on the out side of the flash light use a needle nose pliers and grab hold of the battery metal you folded toward the center and twist and pull the battery out .

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 ?

Thank you!

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.

Perfect video, congratulations !

Just what I needed thank you :)

...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.

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

This really worked. Thanks bro!

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

Worked perfectly. Thanks, man!

Nice video , a little tongue tied there are we ? Lol

I put water in mine and it softened the acid and I hit it on a hard surface and it came out

Thank You!

Would've probably worked if it didn't dig the screwdriver into the back of it.

While following the directions to remove the corroded batteries and putting it all back together, the small metal pin was damaged. Do any of you have an extra one laying around that you don't need and would be so kind as to mail it to me at: Stan Dawson, PO Box 122, Kilmarnock, VA 22482-0122

Thanks. It was a great help.