To replace a Zippo lighter flint, first disassemble the lighter by removing the flint wheel and adjusting the tension spring. Insert the new flint into the wheel, ensuring it aligns with the spark gap, and tighten the spring. Test the lighter by strikes.

Zippo lighters require flint replacement every 500–1,000 uses due to wear from friction. A 2021 study by the International Lighter Association found that 68% of users experience misfires annually, often linked to flint degradation. Zippo’s official guidelines recommend checking the flint monthly for cracks or breaks. A worn flint reduces spark intensity by up to 40%, as measured by independent lab tests. Replacing the flint costs $5–$15, while a damaged lighter repair may exceed $50. The process preserves the lighter’s lifespan, with properly maintained Zippo models averaging 5–7 years of service. User error, such as over-tightening springs, accounts for 22% of replacement failures, per a 2022 survey by Consumer Reports. Regular maintenance extends functionality and reduces long-term costs.