@rajpotus: I had the same problem. If the little rubber tab is not damaged (mine was fine), you should be able to follow these instructions to replace it. But I have these comments on the instructions:
1) You do NOT need to remove the front grill. I have no idea why they suggest you do that here.
2) I think the reason you remove the battery is to make sure the circuit board has zero power on it when you work on it — otherwise a touch of the screwdriver to an unlucky spot on the board might short/burn something out. But I don’t think there’s any mechanical reason to remove it.
3) Once you pop off the back grill cover, you should be able to slide the tab through the slot and coax it up (maybe with a tooth-pick and/or tweezers) on top of the circuit board, but it’s probably better to unscrew the circuit board (as directed here) which makes it easier to push the rubber tab through. Then slide the circuit board back under the tab and screw it back into place.
I just want to emphasize that the rubber tab (that is part of the cover) is supposed to sit ON TOP of the circuit board. In my case, my son managed to pull of the battery cover off completely, so as I was taking it apart I didn’t see how the rubber tab was actually supposed to sit inside the box. Because these instructions have you unseat the circuit board, I thought it was implying the tab was supposed to sit under the circuit board. But that is NOT the case! If I had looked at the pictures 7 and 9 more carefully, I would have seen how things were supposed to sit. Instead I first jammed things back together with the rubber underneath the board (really hard to do), only to find that the slightly squeezed rubber tab pushed the cover out a millimeter so it wouldn’t sit right on the charger. On closer inspection, I figured things out.
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