Battery stuck in main tube
This has happened to me several times. You can begin removing the bulb and reflector from its end of the flashlight. I then get a very long (5 or 6 inch) deck screw, the kind that has very coarse wood screw type threads. I screw this into the swollen battery (you may need to drill a small diameter pilot hole in the botton of the battery) and pull on the screw with pliers to see if the battery will budge. If it wont budge, I then stand the flashlight with the battery compartment up, fill it with water, leave it overnight, drain the water and pull on the deck screw again, this usually removes the battery.
NOTE: The magnesium in these flashlights rapidly corrodes away in the presence of battery leakage, so if the battery has leaked a lot, you may be left with only the undamaged components to use as spare parts to repair other lights.
ALSO: If you batteries have a no-leak guarantee, contact the manufacturer' customer service for your free Maglight. Read More At : 3 Cell D Blue Flashlight S3D116...