Changing the PODLight V1 battery pack

The PODLight features long lasting rechargeable batteries. However, even rechargeable batteries wear out over time and need to be replaced.

These instruction explain how to replace the batteries. Click on any photo for a larger image. These instructions are for the Version 1.

Version 1 PODLights can be identified by counting the LEDs in the flashlight. If your light has 9 LEDs then it is a Version 1.

Remove rubber handle. This is made easier by lifting edge of rubber housing then twisting the rubber housing at the hexagon end of the housing while pulling off.

If you have difficulty removing the rubber housing. Lifting the edge and putting a small amount of water under the rubber housing will lubricate it and make it easier to remove.

Be sure to dry any water before re-assembling.

Slide the black housing out of the clear lens until all four screws in the black housing are exposed.

The led board will move with the housing. Pull straight out and be careful not to break the circuit board.

If you have any difficulty removing the board, take the two plugs out of the yellow end cap and remove it. With the cap off, you can push the circuit board down through the clear tube by pushing down on the LEDs in the flashlight. The chrome reflector will stay in the clear lens.

Remove the four screws holding the black nylon battery housing together.

Open housing.

Unplug the battery pack from the circuit board. Be sure to note the wire position.

Transfer the padding from the old battery to the new battery. The padding keeps the battery tight in the housing. A small piece of foam can be substituted if needed.

Plug the battery into the circuit board and position as shown in photo. The best wire routing is shown in photos. Wires should run in between individual batteries. Be sure that no wires are pinched under battery pack or at either end of battery pack.

Re-assemble light by reversing order of battery removal.

Be sure that no wires are pinched during re-assembly.

Just in case you forgot to check the wire position.

The battery wire plugs in to the far right plug when the LEDs are facing you. The black wire should be above the red wire.