Quick little tutorial to disassemble and repair a 3768 Highway Light.
My 3768 had a battery go south in it at some point, so there is some residue in it. So let’s fix it!
The best tool I found to get these apart is a Lego Brick Separator. You may have something similar. But you definitely want to use something plastic and non-marring. Remove the battery door before starting.
Easiest way is to grab the back end and gently pull it apart to get a gap in the sides. Then start to work the tool in to work the pins loose.
Surprise! The battery compartment is broken. This will prove this light to be extremely difficult to get apart.
You will want a small screw driver to unlock these tabs. I started at the bend using my fingernail to separate the post and used the tool to hold it. Once the tabs are released with the tool, work it in to get a gap. Then work to the lamp slowly to get it separated. Two tools will be better.
So, working slow and using two tools, I worked around the seam and finally got it apart. Because of that break in the battery holder, it was hard to get those pins to release and I just had to force it apart. But, generally they will come apart fairly easy once you get a nice gap around the seam. Work slowly!
But, don’t be fooled, these lights are extremely difficult to get apart. There is a good 3/16” of pin in the socket, and it will make some scary noises as they come out.
For the switch, push in the tabs shown by the arrows toward the center and it will come off. Most of these lights will be crunchy when you operate them. Removing the switch piece and cleaning it, and adding a very small amount of lube helps immensely.
So here you can see how the light works. As the switch is pushed back, the switch center lug will push the contacts together. One wire is soldered to the battery ground lug, and the other wire is soldered to the positive lug. As the switch lug pushes the contact down it is closed and feeds power to the lamp.
Since this light is broken, I’m probably not going to clean it, and put it in the “junk” pile. I’m not too sure if it will even go back together. I bent the posts pretty good YOLO’ing it apart.
When reassembling, ensure the wires are in the post channel and try not to pinch them. Simply press the sides together till there is no gap in the body. And make sure to reinstall the foil reflector.
My 3768 had a battery go south in it at some point, so there is some residue in it. So let’s fix it!
The best tool I found to get these apart is a Lego Brick Separator. You may have something similar. But you definitely want to use something plastic and non-marring. Remove the battery door before starting.
Easiest way is to grab the back end and gently pull it apart to get a gap in the sides. Then start to work the tool in to work the pins loose.
Surprise! The battery compartment is broken. This will prove this light to be extremely difficult to get apart.
You will want a small screw driver to unlock these tabs. I started at the bend using my fingernail to separate the post and used the tool to hold it. Once the tabs are released with the tool, work it in to get a gap. Then work to the lamp slowly to get it separated. Two tools will be better.
So, working slow and using two tools, I worked around the seam and finally got it apart. Because of that break in the battery holder, it was hard to get those pins to release and I just had to force it apart. But, generally they will come apart fairly easy once you get a nice gap around the seam. Work slowly!
But, don’t be fooled, these lights are extremely difficult to get apart. There is a good 3/16” of pin in the socket, and it will make some scary noises as they come out.
For the switch, push in the tabs shown by the arrows toward the center and it will come off. Most of these lights will be crunchy when you operate them. Removing the switch piece and cleaning it, and adding a very small amount of lube helps immensely.
So here you can see how the light works. As the switch is pushed back, the switch center lug will push the contacts together. One wire is soldered to the battery ground lug, and the other wire is soldered to the positive lug. As the switch lug pushes the contact down it is closed and feeds power to the lamp.
Since this light is broken, I’m probably not going to clean it, and put it in the “junk” pile. I’m not too sure if it will even go back together. I bent the posts pretty good YOLO’ing it apart.
When reassembling, ensure the wires are in the post channel and try not to pinch them. Simply press the sides together till there is no gap in the body. And make sure to reinstall the foil reflector.
