Introduction
The lock on my Nikon SB-400 was not working, it was stuck in the lock position and could not be mounted or removed. Ultimately it was a broken mechanism within the flash, but it required a disassembly of the unit to learn this.
Tools
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Remove the SB-400 flash from the camera if able.
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Remember in my case that the flash is unable to be removed from the camera, so remove batteries from both.
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The SB-400 uses two AA batteries.
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Remove the two screws from the bottom of the flash.
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Remove the two screws from under the battery cover.
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If you are not confortable discharging a capacitor, it is recommend to bring the unit to a professional for repair.
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As you can see, a flash capacitor is very large and the risk of shock must be addressed. I discharged it using a screw driver with a plastic handle.
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Remove the two screws holding down the PCB.
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Move the PCB out of the way to expose the battery case. The wires should remain attached.
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Remove the battery case by sliding out the middle spacer and set it aside.
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Leverage the battery case up and forward to remove.
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Move the battery case out of the way, the wires should remain attached.
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Remove the small silver screw holding the ribbon wires in place.
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Remove the four screws that hold the lock plate in place.
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With the four screws removed, the hot shoe (metal plate in contact with the camera) will drop off the flash.
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The reassembly is the reverse of the disassembly.
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Ensure these two fastener holes are clear when the top cover in installed to avoid damaging wires.
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To reassemble your device, follow these instructions in reverse order.