How to Change the Flint Wheel in a Zippo Lighter

Zippo lighter are a favorite among collectors and the general lighter-using public as well. These lighters were especially popular with military servicemen due to their ruggedness and reliability. Often, the flint wheel becomes damaged or worn down and needs to be replaced.

Difficulty: Moderate

Instructions

Things You'll Need:

• Small screwdriver
• Pliers
• Pop rivet gun

1. Find the model of Zippo lighter by inspecting the piece. Many models have their numbers right on the bottom of the lighter. Remove the lighter mechanism and look inside the case as well.

2. Remove the entire contents of the Zippo case. Set the case aside and let the case air-dry. Wipe up any lighter fluid that has leaked from this process.

3. Purchase a new flint wheel from the manufacturer or buy a used identical Zippo lighter to use for parts. Find used Zippo lighters at thrift stores, flea markets and garage sales.

4. Unscrew the flint spring from the unit using fingers or a small screwdriver. The spring unit will slide out of the tube.

5. Allow any lighter fluid in the Zippo to evaporate completely. This process can take a few days but is critical to the project.

6. Pop the rivet on the flint wheel using a needle-nosed pliers and slide wheel from its frame.

7. Place the new wheel into the frame and pop rivet wheel into frame with a small pop rivet gun. See that the wheel travels freely.

8. Reassemble the Zippo by reversing these steps. Fill with lighter fluid and return flint spring assembly.

Tips & Warnings

• Use the existing removed flint wheel by simply removing wheel and turning the wheel around in its frame.
• Send the Zippo back to the manufacturer for repairs. These lighters are warranted for the life of the unit and are repaired free of charge.
• Wear gloves and eye protection for this project.