MAG-LITEŽ AA Switch Replacement

01) Unscrew and remove entire tailcap assembly (16). 02) Remove batteries. 03) Unscrew and remove entire head assembly (1). 04) Remove lamp (8) by pulling it straight out of the receptacles. 05) Insert the switch repair tool (23) with the longest pin protrusion into the bottom of the barrel (12). Rotate the tool until the two pins enter the two holes in the bottom of the lower insulator receptacle (15) by forcing the barrel (12) downward and the tool (23) upward. The upper insulator receptacle (11) will move upward and seperate from from the lower insulator receptacle (15). You can now remove both upper and lower insulator receptacles from the barrel and discard all old switch components (Items 11, 13, 14, and 15). 06) The Switch Component Assembly contains items (11, 13, 14 and 15). Insert the Center Contact Lamp Receptacle (13) into the 'T' shaped slot in the Lower Insulator Receptacle (15). The "Tounge" of the contact will be oriented facing the outside of the insulator. While holding the Center Contact in the 'T' slot with one finger turn the insulator upside down and bend the Tounge of the Center Contact over 90 degrees toward the center of the insulator. (The Tounge will cover the bottom side of the other slot.) 07) Install the Side Contact Lamp Receptacle (14) into the slot of the Lower Insulator Receptacle (15) with the Tounge resting on the outside edge of the insulator. 08) Install the end of the Switch Repair Tool (23) with the shortest pin protrusion into the two holes in the bottom of the Lower Insulator Receptacle (15). Now insert this lowerswitch half sub-assembly into the bottom of the barrel (12) until it "bottoms out" on the upper shoulder of the barrel. 09) While holding the tool, insulator and barrel firmly together line up the slots of the Upper Insulator (11) with the ribs of the Lower Insulators (15). By exerting thumb pressure downward on the Upper Insulator (11) it will lock in place with the Lower Insulator (15). 10) Re-install the lamp (8) into the receptacles of the Upper Insulator. Adjust lamp so that it is vertical and as staright as possible. (This will allow for better focus when the lamp is re-inserted into the reflector (5). Using a clean soft cloth gently wipe the moister and oil from glass on the lamp. 11) All visible seals (6, 10, 19 or 21) should have a light coat of oil on them. If not, lightly coat with petroleum jelly (Vaseline) or other clean household automotive lubricant. 12) Re-install Head Assembly (1). 13) Check batteries for leaks or corrosion. Reinstall or replace batteries. (Two AA Series, Alkaline only- install (+) end toward bulb.) 14) Reinstall Tailcap Assembly (16)- always make sure tailcap is tight for good positive electrical contact.

Tailcap Sub-Assembly (Old and New)	Inspect the tailcap assembly configuration as shown in figures 2 & 3. If Tailcap has a shoulder and 'O' Ring, replace with 'O' Ring Item #19. If there is no shoulder and a Lip Seal, replace with Lip Seal, Item 21. When replacing entire Tailcap assembly always use the (NEW) Lip Seal and Tailcap (Items 21 &22). 08)-AA 407-000-030-Lamp/Bi-Pin (New lights only, not included with tailcap assembly) 16)-AA-103-000-411-Tailcap Assembly w/(Lip Seal) 17)-AA 403-000-008-Spring, Tailcap 18)-AA 403-000-010-Bulb Protector 19)-AA 403-000-007-'O' Ring Tailcap 20)-AA 203-000-003-Tailcap (Old Style) 21)-AA 403-000-020-Lip Seal (New) 22)-AA 203-000-172-Tailcap (New Style)
Head Assembly	02)-AA 203-000-004-Facecap 03)-AA 403-000-015-'O' Ring, Facecap 04)-AA 203-000-007-Clear Lens 05)-AA 403-000-001-Reflector 06)-AA 403-000-014-'O' Ring Head 07)-AA 203-000-002-Head
Barrel Switch Sub-Assembly
08)-AA 407-000-030-Lamps/Bi-Pin 09)-AA 103-000-005-Barrel & Switch Sub-Assembly 10)-AA 403-000-013-'O' Ring, Barrel 11)-AA 403-000-003-Insulator Receptacle, Upper (See Switch Component Assembly). 12)-AA 203-000-001-Barrel 13)-AA 403-000-011-Lamp Receptacle, Center Contact (See Switch Component Assembly). 14)-AA 403-000-012-Lamp Receptacle, Side Contact (See Switch Component Assembly). 15)-AA 403-000-004-Insulator Receptacle, Lower (See Switch Component Assembly). 23)-AA 412-000-012-Switch Repair Tool (See AA Replacement Parts).
Switch Component Assembly	(11)-AA 403-000-003-Insulator Receptacle, Upper (13)-AA 403-000-011-Lamp Receptacle, Center Contact (14)-AA 403-000-012-Lamp Receptacle, Side Contact (15)-AA 403-000-004-Insulator Receptacle, Lower
MAG-LITEŽ AA Switch Replacement