How to Repair Flashlight Switches (Fix Tailcap clicky Switch)
How to Fix the Mechanical Switch in Flashlights (this method Should Work on Most flashlights except the Old Models like Maglite )
Step 1: Gently Pull the Rubber Cap
Step 2: Use Something Thin But Not Sharp to Push the Plastic Housing Out of the Tailcap , Tap It Gently
Step 3: Pull the Switch From the Plastic Housing
Step 4: Measure the Resistance of the Switch to Make Sure That the Problem in the Flashlight Is Caused by the Switch Not From the Pill
Step 5: Use a Thin Object to Pry Open the Switch Through the Holes on the Sides
if your Switch Does not Have Holes on the Sides Then use Something very thin
like a flat head screwdriver to wedge between the Side Crack of the switch (But Be careful not to cut yourself)
Step 6: After Opening the Switch , Clean Its 3 Pins Very Well
Use a metal File or Sand Paper to Remove any Rust from The Surface of the Conductors.
but don't file it too much, Just Scratch The Surface.
Step 7: After Cleaning the Pins, Reassemble the Switch
Step 8: Measure the Resistance of the Switch
Before the Repair The Resistance was 13 ohm, After the Repair, it Became in the Range of 0.01-0.1 OHM , Which means it became as good as new.
Step 9: Put the Repaired Switch Back in the Plastic Housing
Step 10: Insert the Rubber Cap
Step 11: Insert the Plastic Housing , Then Tap It Lightly to Secure It in the Tailcap
Step 12: Connect the Tailcap to the Flashlight and Test It
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