Mag Instrument Inc. manufactures the Maglite heavy-duty flashlight. As with any household item that gets intermittent use, the alkaline batteries inside the flashlight may leak if not changed out regularly. The leaked material may chemically join the batteries to the material Mag uses for the flashlight casing. If you can't remove the batteries mechanically, you can resort to a chemical strategy. Neutralizing the corrosion should allow stuck batteries to come out easily.
Step
Unscrew the head of the Maglite, exposing the bulb. Unscrew the light bulb.
Step
Lift off the on/off button with a flathead screwdriver. Insert a hex wrench (usually 2mm) into the hole that was underneath the button. Insert it all the way down. Unscrew the switch mechanism and slide it out the head of the flashlight.
Step
Set the flashlight on its tail, fill it as high as you can with lemon juice or vinegar and let it sit for a half hour. The tail cap, still in place, will act like a cork, keeping the fluid in.
Step
Empty the reacted solution into the sink. This should be safe, since any alkaline paste coming out will be neutralized.
Step
Try to remove the battery mechanically. Remove the tail cap and push the batteries out, using a broomstick if need be. Lubrication may help if the batteries are swollen. Vegetable oil may work, but an automotive aerosol lubricant may work best. Use enough to get into all spaces between the battery and casing.
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Step
Put the tail cap back on and repeat steps 3, 4 and 5 if the battery is still stuck. If the second try fails to dislodge it, proceed to Step 7.
Step
Fill the flashlight again, but this time with a mixture of baking soda and water, which may help soften the corrosion as well as clean up the mess inside. Putting too much baking soda in the mixture is preferable to putting in too little. Again, let it sit for half an hour.
Step
Empty the solution into the sink and try to dislodge the battery again. In the unlikely event that you still can't get it out, contact Mag (see Tips.)
