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You don't. You bite the bullet and buy a new one. There's a new one on eBay for $77 or you can go to Mouser for $104.25.
I use my Metcal quite a bit and am still on the same handpiece for 15 years but I do have a shiny new handpiece "just in case". Also, my Metcal was bought used on eBay.
G²
Boris Mohar
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May 24, 2017, 4:31:11 PM5/24/17
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Actually I just managed to take it apart. I applied compressed air to the
tip entrance and the guts popped out like a champagne cork.
--
Boris
N_Cook
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May 25, 2017, 3:25:37 AM5/25/17
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So it looks as though the OP may as well carefully "Dremmel" into there
and explore, and hopefully divulge if he finds weak spots, hollows ,
active areas etc
N_Cook
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May 25, 2017, 3:35:26 AM5/25/17
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I'll have to remember that, for the next plastic superglue/welded box I
come across
Chris Jones
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May 25, 2017, 10:46:14 AM5/25/17
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You open those by tapping them with the plastic handle of a screwdriver,
working along the seam. A long time ago mikeselectricstuff showed how to
do it on his youtube channel. I can't remember which video. The
technique works very well.