Tech Forum

Let's first try to understand why a battery cell expands and leaks. Most battery manufacturer's say that this happens ONLY to discharged batteries. In other words, the battery chemical reaction has completely run its course and the chemicals now in the battery are not the original chemicals anymore. The discharged version of the chemicals will eat their way out of the casing and/or expand the casing due to out gassing.

Understanding this, we understand that we MUST NEVER allow the batteries to completely discharge before removing them from the flashlight or child's toy, or whatever. I'm sorry to say, that if you've let the batteries expand so much that they are stuck in the flashlight, the best you can do is to take the bulb out and throw the rest away. But, with a little forethought we can plan for this problem!

The first and best solution is to check your batteries every 6 months and as soon as they start showing any signs of decomposition/leaking, replace ALL of them.

The second solution is to use the new NiMH long shelf life batteries. Since these are rechargeable the chemical reaction does not cause them to expand, and since they are long life you only need to charge them once a year.

The third solution is to buy C-cell to D-cell conversion cases. I've seen these but do not know if they are still available, if you can find them let me know, I believe I saw them in one of my electronics or computer-parts magazines. In any event, use C-cells in these and when they expand they will have room to do so. If you're very lucky you'll be able to clean out the conversion case and reuse it.

I use the first and second solutions at my house, but I also only have one D-Cell flashlight, the rest are the new three AAA cell LED type. When they leak or expand, I can remove them since they are in a three-cell holder that slips into the flashlight. They are as bright as most older standard three D-cell flashlights or brighter, and they last far longer! So far I've always been able to get the case and holders cleaned up enough to use them again. And, if I ever lose one I won't lose much since I only buy the ones that are less that $10.

I hope that helps in preventing this problem for you.

Do an Internet search under "repairing Maglites". You'll find several sites with instructions and/or videos to help you in this endeavor. Look at them all before proceeding.