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Repair for LED, incandescent, and other handheld electric light sources.

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How to remove dead batteries from flashlights?

Does anyone know how to get dead batteries out of flashlights when the batteries have swollen up and wont slide out on their own?

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Brian R , Wear gloves and eye protection. If normal type battery, drill a small pilot hole in battery, use an old cork screw or coarse lag screw threaded into battery(approx. 1/2 way or a little more). If really stuck and corroded you may have to heat the flashlight casing up with a hair dryer/heat gun to aid in removal of batteries. Grasp the cork screw/screw and pull battery out. repeat for second battery if needed. Dispose of old battery in appropriate manner. Video links below may help. Good luck.

I hope this helped you out, if so let me know by pressing the helpful button.

https://www.youtube.com/watch?v=FwARuAc7...

https://www.youtube.com/watch?v=YHXojM5v...

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I forgot to mention this is an AA Maglite. Thank you for the helpful responses!

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I had a battery seize at the very top of my 4 D-cell Maglite. I soaked it in baking soda and water to neutralize the acid. Then used vinegar and baking soda to help break the corrosion sealing the battery to the maglite body. Rinsed thoroughly then used canola oil to get in between the battery and the body. All these steps were done over 48 hours. I then placed the oiled assembly in the freezer for 48 hours. After 48 hours I placed the maglite in the oven for 5 minutes to heat and expand the aluminum body. After 5 minutes of gentle taps on piece of 2x4 on the concrete floor, the battery slid out with relative ease. Note, you should disassemble the flashlight before starting any of the above steps. I drew the lens, the bottom lid, take out the bulb, gently pry off the rubber button then use a 5/64” Allen Key in the button. Wash all parts to remove oil and dry. Clean any residual corrosion from inside the maglite body with a tube brush wash, rinse and dry. Reassemble and viola, you saved your flashlight.

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If this one has both a removable light and removable bottom take both off. You should then be able to get a screwdriver in and help push the batteries out.

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I forgot to mention this is an AA Maglite. Thank you for the helpful responses!

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For removing a stuck (AA) battery - from my camera - this worked like a charm and was least intrusive.

  • I put the camera on it’s side so the stuck battery was facing the ceiling and was COMPLETELY LEVEL.
  • I smeared a little super glue onto the top of the stuck battery but not close to the battery’s edge!!!
  • I placed a thick metal nut on top of and in the center of the battery. The nut must be smaller than the battery.
  • I added extra super glue into the center region of the metal nut.
  • I let it set until the next day. Then, simply used a wrench on the nut to move it until it was free; then could simply extract the battery.

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Needed to remove 3 stuck AAA batteries from a laser level. All metal body and access only to one end (where the battery cap goes). Battery #1 came out after a lot of prying. Battery #2 was stuck. I tried a long narrow pick, WD-40, baking soda solution. Nothing.

I finally found a long decking screw and drill bit long enough and drilled a hole into the top of battery #2. Was able to drive the screw in far enough that I could pull the stuck battery out. #3 was also stuck, but I was able to loosen it with a long, narrow flat head screwdriver. Ugghh…. not pretty, but it worked.

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Brian R will be eternally grateful.
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