A tip I overheard given to a customer at the old Maglite Warranty/Repair Center, was to apply rubber epoxy on the bottom of the switch cover and switch before replacing the switch cover. This helps retain the switch cover in place. Many users carry their C and D cell Maglites (and Magchargers) in "ring" type flashlight holders worn on their belts. Each time the flashlight is removed and replaced from this type of holder, the switch cover strikes the ring because it sticks up slightly above the flashlight body. Eventually, the switch cover falls off. Over the years, I've found several of these covers lying around the office where I work out of (for many years, the company I work for issued 3-D incandescent Maglites with a "Law Pro" leather and metal ring holder). If I observed a co-worker's flashlight missing the switch cover, I'd give him one of the covers I had collected. I still have a few of these covers lying around. The new electronic switches Maglite is using have smaller switch covers, and are more recessed into the body. This may have solved the problem, or at least reduce the chances of it happening.