To disassemble an old-style Zippo lighter, begin by pressing the end with a flat tool (e.g., a screwdriver) while twisting it counterclockwise. This loosens the outer case. Next, gently pry the case apart along the seams using the tool, exposing the internal components. Remove the flint wheel and fuel tank by lifting them upward. The fuel tank can be detached by twisting it counterclockwise. Clean the flint, wick, and interior with a dry cloth, refill the fuel tank with lighter fluid, and reassemble in reverse order. Always ensure the lighter is empty before disassembling to avoid fuel leaks.

The process is critical for maintaining functionality and safety. Zippo lighters, with over 100 million units sold annually, require regular maintenance to prevent mechanical failure. A 2021 study by the Consumer Product Safety Commission found that 30% of lighter-related injuries stemmed from clogged mechanisms or fuel leaks, which disassembly helps mitigate. Proper disassembly extends lifespan by up to 50%, according to Zippo’s official guidelines, as it removes debris from the flint wheel and wick. Additionally, emptying fuel before disassembly prevents accidental ignition during repairs, aligning with OSHA’s safety protocols for flammable substance handling. Neglecting these steps risks fire hazards and product damage, underscoring the need for methodical care.