The switch stopped working in my Mini Maglite AA. I bought a replacement switch over the Internet and fixed it, and then I found out that Mag Instruments would have sent me a new one free under the lifetime warranty. Too bad.
The problem was that the light turned on erratically if at all, and didn't focus properly.
If you open the top, you'll see that the bulb is stuck into a washer-like receptacle which they call the Upper Insulator Receptacle. It's printed "Do Not Remove."
If you remove it, by prying it up with your thumbnails or a pocket knife, you'll see the switch assembly underneath, with a triangular-shaped sheet metal slide contact. Remember how the slide contact goes, because it's likely to fall out. If you remove the batteries, you can take out the lower insulator too. That slide contact is what failed on me. Instead of being flat, the radial arm was bent. I think that if I had flattened it out with needle-nosed pliers, that would have fixed it, at least for a while.
Anyway, the "Switch Repair Kit" comes with the most idiot-proof detailed illustrated step-by-step instructions that I've ever seen for any piece of equipment. They even give you a plastic "tool" to insert and remove the switch, if you're the kind of person who has trouble tapping a flashlight onto a table without losing parts, or you don't have a pencil lying around the house.
Get more detail about Mag Lite Mini AA Maglite Blister Pack.
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