Anatomy Of The Maglite Mini Mag 2AA Flashlight Switch


This is the MagLite Mini Mag 2AA with wrist lanyard, which we will be looking at today.


To begin disassembly, we twist the head off by turning it in a counter clockwise direction. The head contains the reflector, so removing the head leaves the bulb exposed --which is how it works in candle mode. In our case, the flashlight has been upgraded with a Terralux LED bulb. If your model has an incandescent bulb, the anatomy of the light will still be the same, but the bulb itself will look different.


The two bulb pins are inserted into the switch. When a Mini Mag does not work, and the bulb and batteries are good, the switch is the part we want to check. So pull the bulb out, and the outer part of the switch will be revealed. The switch consists of two different parts. The part you see here is the outer part of the switch, and has the words "DO NOT REMOVE" stamped on it. And unless you want to fix the light, this is good advice to follow. But to get to the inner switch, this piece does need to be removed.


The outer switch is one piece of plastic that is pressed into the inner part of the switch with two stems. It is removed using Maglite's switch removing tool, also known as the replacing tool. The removal tool is shown here, ready to be inserted into the body of the Mini Mag. The tailcap and batteries were removed and set to the side. It isn't a big difference, but the tool's stems on either end are different lengths. The longer of the two lengths is used to remove the switch, and the shorter are used to put the switch back together.


Pushing the switch tool down the barrel, one can feel the tool's stems inserting into holes at the end of the barrel. These holes are part of the inner part of the switch. With a little more effort, the outer platform's stems will be pushed out from the inside of the Mini Mag. With the platform off you can see the two stems.


The out part of the switch is what held the inner part of the switch inside the barrel of the Mini Mag. So when the switch removal tool is pulled out of the barrel it will frequently have the inner part of the switch on it. If not, tap the rear of the Mini Mag on the palm of your hand and the inner part of the switch will fall out in your hand. If that doesn't work then just push the inner part of the switch out with the switch removal tool placed into the holes at the front of the Mini Mag where the outer part of the switch would go. Be careful to note if a contact fell out as soon as you can see the inner part of the switch.


There is a small strip of metal that goes from the center of the inner part of the switch to the outer edge of the barrel. This is the negative contact of the switch. Use caution, as that strip of metal can fall out. If these contacts fall out and are not placed back into the Mini Mag switch correctly, it will stop the light from working. These contacts are very small so be careful as soon as the outer part of the switch is removed.


Once the inner part of the switch is removed it shows the positive contact as a small round piece of metal in the center of one side of the switch.


If the contacts do fall out of the switch, they can easily be replaced. But if the contacts are not placed back into the switch correctly, the Mini MagLite will not work.


The switch is now ready to be placed back into the barrel for re-assembly. Place the small stems of the tool into the holes on the positive side of the inner part of the switch and push the inner part of the switch back into the barrel of the Mini Mag.


Holding the tool firmly in place while you push the stems of the outer part of the switch into the holes of the inner part of the switch as it is held at the front of the Mini Mag with the tool completes the switch assembly.


Replace the bulb, head, batteries, and tailcap. You should now have a functioning Mini Mag.

Other Information & ArticlesList All