Firearms Inspection and Troubleshooting

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ISBN:978-1-945697-32-6
Content written by: Frank Vigil
Cover image by: Oleg Volk

Course materials and other works have been prepared by or on behalf of SDI for general informational and educational
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Rev. 6.21
 Firearms Inspection and Troubleshooting
Contents

Chapter 1 - Troubleshooting, Maintenance, and Firearm Repair . . . . . . . . . . . 1

Chapter 2 - Troubleshooting Break- and Bolt-Action Firearms . . . . . . . . . . . 35

Chapter 3 - Troubleshooting Lever- and Pump-Actions . . . . . . . . . . . . . . 69

Chapter 4 - Troubleshooting Revolvers . . . . . . . . . . . . . . . . . . . . . . . .91

Chapter 5 - Troubleshooting Blowback Actions . . . . . . . . . . . . . . . . . . . 111

Chapter 6 - Troubleshooting Recoil-Operated Actions . . . . . . . . . . . . . . 127

Chapter 7 - Troubleshooting Gas-Operated Actions . . . . . . . . . . . . . . . . 147

Glossary of Firearm Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 165

 Chapter 1 - Troubleshooting, Maintenance, and Firearm Repair
INTRODUCTION 3
FIREARM INSPECTION PROCEDURES 5
Safety 5
Tools and Materials 8
Function and Safety Check 9
HEADSPACE 23
TEST FIRE 27
 Introduction
Like any machine, firearms are prone to mal-
function and require a certain amount of main-
tenance. Firearms are also likely to experience
parts breakage and require repair. A gunsmith
should be able to diagnose any issues that may
be caused by the firearm and ammunition or
by the shooter themselves. There are certain
procedures that should be followed to properly
troubleshoot any issues that you may encounter.

3
 Safety first! Use appropriate eye and ear protection.

Safety first! Keep your finger off the trigger until you are ready to shoot.

4
 2. Never point a firearm at anything you do

Firearm Inspection not intend to destroy.

Procedures
3. Know how to safely operate your firearm
and how all of its safeties work.
4. Use appropriate eye and ear protection.
Anytime you are working with firearms, safety
5. Always keep firearms unloaded until
is the most important consideration. Every as-
ready to use.
pect of the inspection procedure is designed to
ensure your safety and the safety of the opera- 6. Live ammunition is not allowed in the
tor. The inspection procedure includes an initial work area.
safety check, followed by a function check, and
finally a test fire. 7. Never use live ammunition to function
check firearms; use snap caps only.
SAFETY Because you may have to test fire a firearm to
verify function, there are a few more rules to
Working with firearms is not as dangerous as
adhere to:
some would assume, but there are inherent dan-
gers that can be nullified with a few basic safety 1. Keep your finger off the trigger until you
rules. These rules will ensure your safety and the are ready to shoot.
safety of everyone around you at all times. 2. Know your target and what is beyond.
1. Treat every firearm as if it were loaded.
3. Always use caliber-correct factory
ammunition.

Figure 1: Clearing a firearm.

5
The first step in preparing any firearm for in- in the chamber. If the firearm utilizes a
spection is to clear it. Clearing a firearm involves fixed magazine, you may have to manu-
removing its feed source, ammunition, and mak- ally cycle the action several times before
ing sure the chamber is clear. Clearing a firearm all the cartridges are removed from the
is always done in the same sequence; failing to action. Once the action is clear, manually
complete the sequence in order can lead to a cycle the action several more times to
very dangerous situation. The steps to clearing verify. For revolvers, use the ejector rod
any firearm are: to empty the chambers in the cylinder.
1. Set the firearm’s selector/safety to the 4. Lock the action open (if possible) and
“safe” position. Some designs will not physically and visually check the cham-
allow you to set the safety as it will inter- ber. Use your finger to feel inside the
fere with clearing the action (i.e. 1911). chamber and look to verify it is clear.
2. With repeating and semi-automatic fire- If the firearm utilizes a fixed magazine,
arms, remove the feed source. This means verify the magazine is empty and you can
any box, drum, or detachable tubular see and feel the magazine’s follower.
magazine. For revolvers, unlock the cylin- The firearm is now clear and safe to handle.
der or open the loading gate. For firearms Remove any live ammunition from the work-
that utilize a fixed internal or tubular space and the room to prevent any accidental
magazine, unlock and open the action. loading. If there is ammunition left in any feed-
3. Unlock and open the action to manu- ing devices, remove it as well. If you need to
ally extract and eject any cartridges left function test the firearm at any point, use snap

Figure 1b: Removing the feed source.

6
Figure 1c: Extracting and ejecting.

Figure 1d: Action locked open.

7
caps or “dummy rounds” to ensure you are doing • Screwdrivers – flat and Phillips-head
it in the safest way possible.
• Wrenches – box and open-ended, adjust-
At some point, you will have to test fire a fire- able, socket, torque, Allen, torx and strap
arm to verify function. Make certain you are
pointing the muzzle of the firearm at an appro- • Pliers – combination, slip joint, needle-
priate backstop when loading the firearm and nose, Channellock, and vise grip
anytime there is a live round in the chamber. • Picks
Even if you need to hand-cycle live rounds to
verify function, always point the firearm at an • Tweezers
appropriate backstop.
• Hemostat
TOOLS AND MATERIALS • Files, stones, and sandpaper

You will need certain tools and material to dis- • Clamps

assemble and assemble a firearm during mainte-
• Vise
nance and repair. Make certain you have every-
thing you will need near you ahead of time; you • Caliper
do not want to be looking for a tool while trying
• Levels
to hold another assembly together. A basic tool
list includes: • Magnetic parts tray
• Hammers and mallets – ball-peen, brass, • Sandwich bags
hybrid and rawhide
• Shop rags
• Punches – starter, pin, roll pin, center
and drift • Cleaning kit – patches, jags, brushes,
rods, cleaner and oil

Figure 2: Basic tools and materials.

8
• Masking tape or binding. With manual actions, it is easier
to work the action slowly in both the unlock-
• Small light
ing and locking strokes. With semi-automatic
• Snap caps firearms, it is slightly more challenging because
you are fighting against the action/recoil spring
• Specialty tools – barrel and action and you hand-cycle the action. Work the action
wrenches, barrel nut wrenches, trigger slowly so that you can feel each step of the cycle
pull gauge, scale, etc. of operations. There are several steps of the pro-
cess that you should feel, depending on action
FUNCTION AND SAFETY CHECK type. These things include the following:

The function and safety check is the second step • Unlocking – When hand-cycling the
in the troubleshooting and repair processes. The action, the first thing you should feel is
function check is used to diagnose any issues the breech unlocking on almost every
that the firearm may be experiencing. The func- action type, except blowback. The action
tion check is performed by hand (no live fire) in unlocking will feel like light or moder-
a controlled environment. ate resistance as the locking lugs/surfaces
shear across each other. You will feel the
The initial function and safety test should be moment the breech unlocks as the bear-
done “dry,” meaning there are no snap caps or ing surfaces clear each other and the
live rounds involved. The action is manipulated resistance that was felt lessens.
by hand slowly, paying close attention to the
“feel” of the action parts moving together. The Outside of feel, you can also hear the
parts should feel smooth when moving against sounds of the breech unlocking. You can
each other and there shouldn’t be any stoppages typically hear the bolt move, camming

Figure 3: Unlocking the breech by hand.

9
 Figure 4: Cocking the hammer.

and rotating inside the carrier or receiver, until the sear catches and the hammer is
or the barrel camming and unlocking trapped. With double-action revolvers,
from the slide. You may also hear vari- you will have to press the trigger slowly
ous clicks or pings as the action performs so that you can feel the movement of the
other tasks like disconnecting the fire action. You may have to use two fingers
control group (FCG), or moving the to move the trigger slowly and really feel
elevator/carrier. the action move.

Once the breech has unlocked, the feel • Cocking – Once the action is unlocked
of the stroke should be smooth until you and has reached the end of its stroke, you
reach near the end of the stroke. A blow- will feel the FCG cocking. You will begin
back firearm should feel the same all the to feel resistance and you may hear several
way through its stroke, until it reaches clicking sounds as the hammer/striker and
the cocking step. Break-action firearms sear are engaged. The feel of the cocking
should pivot open smoothly once the top step will vary depending on whether the
lever is manipulated. firearm utilizes a hammer or a striker.

The unlocking step will feel much dif- With a hammer-fired action, the bolt/
ferent for revolvers. Because all of a re- carrier/slide will engage the hammer
volver’s action movement comes from the almost immediately after unlocking or
FCG, you will have to dry fire it to verify shortly after. You will feel resistance
function. With single-action revolv- as the bolt/slide forces the hammer
ers, you will need to cock the hammer around the hammer pin until the
manually and feel for the cylinder stop to sear engages the hammer and traps
release the cylinder and the finger to turn it. Depending on the action, you may
the ratchet. Cock the hammer slowly feel the bolt move past the hammer

10
as it travels rearward, or you will feel With striker-fired actions, the striker will
continuous pressure throughout the have to ride over the sear on its rearward
stroke, like with semi-automatic pistols. stroke and be arrested by the sear on its
Once the action begins its forward stroke, forward stroke. On the rearward stroke,
the bolt/carrier may have to ride over the you may feel some resistance as the strik-
hammer and you will feel slight resistance er pushes the sear out of the way and you
once more. may hear a click as the FCG disconnects
and the sear pops back up. On the bolt’s/
With single-action and double-action slide’s forward stroke, the striker is cap-
revolvers, the hammer is manually cocked tured by the sear before the breech closes
by pressing against the hammer’s spur completely. You will feel slight resistance
and forcing the hammer downward until as the forward stroke of the bolt/slide
the hammer is trapped by the sear. The overcomes the striker spring and cocks it.
hammer should feel very stiff as you As you move the bolt/slide forward, you
overpower a heavy (16 – 20 lb.) hammer can feel resistance as the striker is pulled
spring. With some break-action firearms, rearward, placing tension on the striker
the hammer(s) is cocked by a cocking spring and cocking it.
lever. When the action is opened, a lug on
the barrel(s) acts upon the cocking lever • Locking – As you continue to drive the
(in the receiver) and cocks the hammer(s). action forward, the last thing you will
When you pivot the action open, you can feel is the breech locking. Like unlock-
feel slight resistance as the leverage of the ing, you will begin to feel a light to
barrels and receiver/stock aid in overcom- moderate resistance as the locking lugs
ing powerful hammer springs. or surfaces engage. With manual actions,

Figure 5: Locking the action.

11
 you will have to force the breech closed Unlike the first check, the second check relies
with light to moderate force until the more on vision than feel. You can watch the
action bottoms out and locks. With dummy rounds as they complete various stages
semi-automatic actions, the action/recoil of the cycle of operations. There are several steps
spring assists with locking the breech. of the process that you should watch, depending
With the action partially locked, release on action type. These things include:
the charging handle/slide and allow the • Feeding – As you slowly hand-cycle
action/recoil spring to lock the breech the action, the first thing you will see
completely. If the breech does not lock is the dummy round traveling into the
fully, there may be an issue. chamber as it is being fed. Depending
Break-action firearms lock when the on the type of action, the round is fed
barrels and receiver are closed and the by hand (single-shot) or from a feeding
top lever resets back into its locked posi- device (repeater). Watch the travel of
tion. You can feel the breech lock as you the dummy round for any hesitation or
watch the lever move. Revolvers will lock disruption in its movement.
almost simultaneously when the ham- With single-shot and revolver actions,
mer reaches its cocked position. Linkage you can feel for any resistance as you
inside of the frame connects the lock and feed a round into the chamber by hand.
hammer to ensure there is no out-of- You can feel any resistance or snagging
battery discharge. As you manipulate the from burrs around the mouth of the
trigger or hammer, you can hear, feel, and chamber or from rough machining inside
see the lock engage the cylinder. the chamber. If you are using brand new
Now that you have completed a “dry” function dummy rounds, you may be able to see
and safety check, you can perform the same scratches on it from the rough chamber.
check using dummy rounds or snap caps. Any With repeating actions, you can watch
issue that did not reveal itself during the initial the snap cap as the action feeds it
check may reveal itself during this check. Like through the cycle of operations. The
the first check, this check is done slowly, exam- first thing you will see is the dummy
ining the snap cap as it travels through the vari- round being stripped from the feeding
ous stages of the cycle of operations. device (fixed or detachable). Watch as the

Figure 6: Feeding a single-shot and revolver action.

12
 Figure 7: Feeding a repeating action.

breechblock/bolt/slide pushes the round over the rim of the cartridge with some
from the magazine or up the lifter/eleva- designs. You may have to force the action
tor. The round should move smoothly, forward so the extractor clears the case
with little to no disruption as it is pushed rim and seats in the extractor groove of
from the feeding device, up the feed the cartridge’s head.
ramp(s) and into the chamber. As you
continue to manipulate the action, you Extracting – After the dummy round
should see the round feed completely into has been chambered, as you manipulate
the chamber, seat, and the breech close the action open, you will see the round
and lock. If the round is not completely being extracted from the chamber. As the
seated, you may see a slight gap in the action moves rearward and the breech
breech or the bolt handle may not bot- opens, you can watch as the extractor
tom out. You should not have to force the pulls the dummy round from the cham-
breech closed with a snap cap or dummy ber by the head of the cartridge case.
round in the chamber; the breech should The extractor should maintain hold of
close with the same amount of force with the case until (and even after) the round
or without the snap cap. Another thing has cleared the chamber. The extrac-
to watch for is the extractor jumping tor should not slip off of the case rim at
any point. The snap cap should move

13
 Figure 8: Slowly extracting the snap cap. Figure 9: Extracting from a break-action firearm.

smoothly from the chamber and should cap from the chamber, there should be
not exert much resistance against the no resistance; the round should come
extractor claw. out easily.

Break-action firearms will extract as the The extraction step for revolvers occurs
action is open. Unlike other firearms when the loading gate (single-action)
where the extractor “pulls” the round or cylinder has been opened. When the
from the chamber, break-action extrac- ejector rod is depressed, you can see and
tors will “push” the round out. As the feel the round(s) being pushed from
action opens, you can watch the dummy the chamber. With revolvers, extraction
round begin to rise as you pivot the is quickly followed by ejection. There
barrel around the action. The dummy should be no resistance (other than the
round is only partially extracted by the ejector rod return spring) when extract-
extractor; you must extract the round ing and ejecting the dummy rounds.
manually. When you remove the snap Also, because you are manually ejecting
the round(s), they will not travel very far.

• Ejecting – As you continue the action

through its stroke, the next thing you will
(typically) see is the dummy round be-
ing ejected from the breech. Because you
are slowly hand-cycling the action, the
round may not travel very far or may just
fall from the extractor’s claw. It is also
dependent on the type of ejector being
employed, fixed, or sprung.

Fixed ejectors, as their name implies,

are fixed to the frame or receiver, while
the round is pulled into it and ejected.
Sprung ejectors are continuously try-
ing to force the round from the breech.
A plunger, typically located on the bolt
face, is continuously applying force to
Figure 10: Extracting and ejecting rounds from a the head of the cartridge case, while the
revolver. extractor is pulling against the case head.

14
 Figure 11: Hand-ejecting with a fixed ejector.

These opposing forces make the case carefully, you will see the ejector force the
pivot around the extractor’s claw and case around the extractor claw, pushing
“spin” out of the breech. the case into the side of the chamber and
then receiver. Once the tip of the dummy
With fixed ejectors, slowly manipulating round is clear, the round will be ejected
the action and trying to eject the round from the breech and away from the fire-
is almost comical. More often than not, arm. Unlike fixed ejectors, this action
the dummy round will slip out of the can occur during low speed hand cycling.
extractor’s claw and fall into the breech The ejection process is magnified when
before ever reaching the ejector. This ap- the cycle is sped up.
plies to both manual and semi-automatic
actions. For proper ejection, you will Now that you have completed a function and
need to accelerate the action so that the safety check using dummy rounds or snap caps,
round has enough energy to bounce off assuming everything passed, you can now run
of the ejector and out of the breech. It is the same check “at speed.” This means you can
often difficult to gauge the ejection pat- accelerate the speed at which you manipulate
tern of the firearm when hand-cycling manual actions and you can allow semi-
because the snap caps will eject in such automatic actions to move under recoil spring
an erratic pattern. force. This check may reveal issues that the
previous checks did not. Because this check
With sprung ejectors, you can see the is done at an accelerated pace, it may be more
ejector trying to force the case from the difficult to see or feel what is happening as the
breech from the moment the case is ex- dummy round is being cycled, especially with
tracted from the chamber. If you watch semi-automatic actions.

15
 Figure 12: Hand-ejecting with a sprung ejector.

At this point, the only thing you are checking

for is malfunctions. The firearm should perform
all of the functions of the cycle of operations
without failure. With snap caps, you are look-
ing for failures to feed, extract, and eject. With
each type of malfunction, you must diagnose the
area of the firearm that caused the malfunction.
Things that you should look for include:
• Failure to Feed – With a failure to feed
malfunction, note the area of the action
where the dummy round becomes stuck
or has hung up. There are many areas of
the action that can cause a failure to feed,
including the feeding device or various
parts of the action, as well as the am-
munition used. Starting with the feeding
device, the round can be disrupted by Figure 13a: Causes of failures to feed - feeding devices.
any part of the feeding device, including
the body, follower, and magazine spring.
Moving into the action, the round may
hang up on the feed ramp(s) located on

16
 Figure 13b: Causes of failures to feed - firearm.

the frame or barrel. The breechblock/

bolt/slide can also upset the round’s
travel. Moving farther, the chamber and
locking lugs/surfaces can contribute to
malfunctions. Damage, burrs, wear, ma-
terial failure, tolerance error, dirt, and
debris in any of the areas that control
feeding can all contribute to malfunction.

• Failure to Extract – With failure to ex-

tract malfunctions, the number of parts
or assemblies that can contribute to the
malfunction is much smaller. A failure
to extract malfunction may be a result of
the chamber or extractor assembly. This
Figure 13c: Causes of failures to feed - ammunition.

17
 includes the body of the extractor, its safety of the fire control group (FCG). While
claw, and possibly an extractor spring(s). the firearm may pass a basic function check, the
Damage, burrs, wear, material failure, FCG is a different story. Using snap caps, you
tolerance error, dirt, and debris in any of can verify that the FCG is functioning properly.
the areas that control extracting can all 1. With snap caps in the chamber (and
contribute to malfunction. feeding device if applicable) and the
• Failure to Eject – Failure to eject mal- FCG in the cocked position, set the
functions can only be caused by a limited safety/selector in the “safe” position.
number of parts or assemblies as well. 2. Depress the trigger. Depending on the
Typically, only the ejector is responsible trigger action type (single-/double-ac-
for failure to eject malfunctions. This in- tion, single-/two-stage), the trigger may
cludes the ejector and possibly and ejec- move slightly or may not move at all.
tor spring. Damage, burrs, wear, material
failure, tolerance error, dirt, and debris in 3. Release the trigger and move the safety/
any of the areas that control ejecting can selector to the “fire” position. Nothing
all contribute to malfunction. should happen.

Once the firearm has passed the initial function 4. Depress the trigger once again. The
checks, both dry and with snap caps/dummy hammer/striker should release, providing
rounds, you can now verify both the function and an audible “click.”

Figure 14: Causes of failures to extract.

18
 Figure 15: Causes of failures to eject.

5. With repeating firearms, (if possible) Firearms equipped with addition (redundant)
continue depressing the trigger as you grip safeties and trigger safeties, as well as out
manually cycle the action, ejecting one of battery “safeties,” require additional safety
snap cap and feeding another. You may checks. For these firearms, the check includes
hear audible cues as the FCG discon- the following:
nects and you may feel it in the trigger. 1. With the FCG set to the cocked posi-
6. Release the trigger. You may hear or feel tion and the manual safety/selector set
the FCG resetting in preparation for to “fire,” depress the trigger without
firing once again. When the trigger is depressing the grip or trigger safety. The
released, hammer or striker should not trigger may move slightly, but the ham-
move. mer or striker should not fall.

7. Using a rubber/nylon hammer or raw- 2. Pull the action slightly out of battery and
hide mallet, tap the receiver/action or depress the trigger. The trigger may move,
FCG housing. Use light to moderate but will feel “free” or “dead” because it is
force. This simulates being dropped or disconnected from the remainder of the
bounced around. The hammer or striker FCG. The hammer or striker should not
should not move. move, even with all safeties deactivated.

8. Set the safety/selector to “safe” once again. Firearms that are equipped with decocker “safe-
Tap the firearm with the hammer or mal- ties” can cause some confusion. Often, when
let once more. Nothing should happen. the decocker is set to the “safe” position, the

19
 Figure 16: Function checking the FCG.

hammer will fall. This can be alarming if you do

not understand how a decocker works. When
the decocker is manipulated, a transfer bar that
transfers the force of the hammer into the firing
pin is removed from the path of the hammer.
The body of the decocker features a lug or tab
that moves the sear and drops the hammer onto
a solid part of the decocker and not the trans-
fer bar. Because these types of systems are al-
most always double-action, when the decocker
is released, the trigger can be depressed and the
hammer will fall onto the transfer bar.
One final area of the FCG to examine, which is
specific to hammer-fired firearms, is the ham-
mer/sear engagement. This can be done with
a snap cap and the hammer set to the cocked
position. Press against the back of the hammer
or lightly tap it with a rubber or rawhide mallet.
The hammer should not move. This test may
also reveal issues with the hammer/sear angle.
Watching the hammer as the trigger is de- Figure 17: Function checking additional safeties.
pressed can reveal clues about the condition of

20
 Figure 18: Function checking a decocker.

the sear and its angle of engagement. Positive

sear engagement is considered the safest condi-
tion and can be identified by the hammer’s slight
rearward movement as the sear moves across the
hammer’s engagement surfaces. Neutral engage-
ment, which is considered to be the best com-
promise of safety and “feel,” can be identified by
the lack of movement by the hammer as the sear
moves across its engagement surface. Negative
engagement, which is extremely unsafe, can be
identified by the hammer’s forward movement
as the sear moves across the hammer’s engage-
ment surface. Figure 19: Checking hammer/sear engagement.
If at any point the firearm does not pass a cer-
tain check, delay the remaining checks until the

21
 Figure 20: Sear engagement angles.

problem is addressed. This means the parts or

assemblies must be cleaned, repaired, reprofiled
or replaced. Do not move forward with any oth-
er function checks until the initial issues have
been resolved. If the firearm has passed all of
the initial checks, you can move forward with
the next step.

22
 the case. Centerfire pistol chamber headspace is

Headspace measured from the breech face to the mouth of

the case. Bottleneck centerfire rifle cartridges
headspace against (roughly) the center of the
Headspace is one of the most critical dimen- case’s shoulder, which is called the datum or
sions of any firearm. In fact, headspace is so datum line. Centerfire bottleneck chambers are
critical that +- .001 in. can be the difference measured from the breech face to the datum
between a firearm that is safe to fire and a fire- of the case’s shoulder. Belted magnum center-
arm that is dangerous. Headspace represents fire rifle cartridges headspace against the top of
the dimensions of the chamber, from breech the belt of the case. Belted magnum centerfire
face to the point in the chamber where the car- chambers are measured from the breech face to
tridge’s case bottoms out. Each cartridge type the top of the case’s belt.
will headspace against a different point of the Headspace problems can lead to a variety of
case. The Sporting Arms and Ammunition issues, ranging from feeding and locking mal-
Manufacturing Institute (SAAMI) closely reg- functions to a destroyed firearm and severe in-
ulates both chamber and ammunition specifica- jury. Too little headspace (short chamber) and
tions and dimensions, standardizing both across the cartridge may not fully seat, the breech
the industry. may not lock, and if both occur, you may ex-
Rimfire, rimmed centerfire, and shotgun car- perience pressure spikes. Too much headspace
tridges all headspace against the rim of the case. (long chamber) and the case can expand beyond
Headspace for these cartridges is measured its capabilities and explode inside the chamber.
from the breech face to the top of the rim of the There is an allowed tolerance for each cartridge
case. Centerfire pistol cartridges typically head- type to operate safely within ranges from .005
space against the leading edge of the mouth of in. to .010 in. This means that the chamber

Figure 21: Headspace point of each cartridge type.

23
 Figure 22: Headspace issues.

can vary in size from the absolute safest mini- No-Go gauges represent a large (long) and possi-
mum to the absolute safest maximum ~.006 in., bly unsafe chamber, while Field gauges represent
which is roughly the size of two pieces of paper. a chamber that is too long and very dangerous.
Headspace should be checked when performing For example, a .223 Remington chamber is
a function and safety check on older, used, ne- 1.4636 in. from breech/bolt face to datum
glected, damaged, and malfunctioning firearms. and has a length tolerance of +.005 in. A .223
Brand new, factory firearms will typically never Remington Go gauge measures 1.4636 in. from
need headspace checked, unless there is an issue. base to datum, while a No-Go gauge will typi-
Headspace can be easily measured using pre- cally measure 1.4686 in. from base to datum. A
cision instruments called headspace gauges. .223 Remington Field gauge measures 1.4696
Headspace gauges are precisely machined to in. from base to datum, .001 in. greater than
represent the exact shape and dimensions of the allowable safe maximum. Headspace gaug-
a properly machined chamber’s headspace. es can be found at various retailers, including
Unlike snap caps and dummy rounds that are Brownells.
meant to simulate a live cartridge, headspace Before you can use a headspace gauge, you must
gauges may look like a partial representation of first remove the extractor and possibly the ejec-
a cartridge. Headspace gauges are available for tor*. If you try to use a headspace gauge with the
every SAAMI specs cartridge, as well as many extractor (and possibly ejector) installed, it could
wildcat cartridges. give a false reading as the gauge may be indicat-
Headspace gauges typically come in sets, with ing off of the extractor (or ejector) instead of the
two to three gauges each. The sets typically con- breech/bolt/slide face. Once the extractor (and
tain Go, No-Go, and Field gauges. Go gauges possibly ejector) are removed, you can feed the
represent the absolute minimum (shortest) size gauge into the chamber by hand. Slowly close
the chamber can be to safely and reliably operate. the action on the gauge in the chamber.

*Only applicable to sprung ejectors, located in the breech/bolt

face.

24
 Figure 23: Headspace gauges.

If you are using a Go gauge, the breech should firearm is dangerously out of spec and requires
close completely and lock on the gauge. If the immediate attention. The firearm is unsafe to
action does not close completely or fully lock, fire and must be repaired before it can be used
this is an indication that the chamber may be too again. If the action will not close on a Field
short, the breech/bolt may be out of spec, or the gauge, but will on a No-Go gauge, the firearm
chamber/bolt/breech face is packed with debris may still be safe to fire but will need to be test
and deposits of carbon and unburnt propellant. fired to verify.
The action should not require a great amount of
force to close either; the action should lock with
light to moderate force. Do not try to force the
action closed.
If you are using a No-Go gauge, the breech
should not close completely or lock on the
gauge, but there is a possibility that it might. If
the action will not close or lock using a No-Go
gauge and will close and lock using a Go gauge,
your chamber is safe, within specification, and
does not require further inspection. If the action
closes and locks with ease on a No-Go gauge,
there is definitely cause for concern and further
inspection is required. If the action closes and
locks, but requires a moderate amount of force
to close, there may still be an issue and further
inspection is required. Do not try to force the
action closed.
If you are using a Field gauge, the breech must
not close or lock on the gauge. If the action does
close on the Field gauge, the headspace of the Figure 24: Using headspace gauges.

25
THIS PAGE INTENTIONALLY BLANK

26
Test Fire
Once you have completed the various func-
tion and safety checks and the firearm has been
deemed safe, you may now perform a “live” test
fire. Although the initial “dry” checks are re-
quired, the live fire test is the only definitive test
of the firearm’s function and safety. The live fire
Figure 26: A face shield, heavy duty gloves, and a thick
test will reveal any issues that the firearm may apron.
be experiencing as well as add additional factors
as to why those problems are occurring. These
additional factors include the action’s function The most important thing to consider when test
under operating conditions, the ammunition, firing is safety. Because the greatest risk for in-
and the operator. jury can occur during the test fire, all firearm
These added factors may make diagnosing the safety rules apply. As long as all of the initial
firearm more difficult, especially when the first function and safety checks passed and the head-
time you are experiencing them is during a cli- space check was within spec, the test fire should
ent’s description of the issue and their exact go smoothly and safely.
words are “The thingy is jamming.” Now you are Extra precaution should be taken when test fir-
left trying to recreate a malfunction that may ing an unproven firearm. Outside of the eye and
not have ever been the firearm’s fault. To effi- ear protection that you should already be using
ciently and safely test fire any firearm, there are when shooting, a face shield, heavy duty gloves,
a few things that you must do to prepare. and a thick apron can add a layer of protection

Figure 25: Test firing a semi-automatic pistol.

27
and a degree of confidence. These items will this point, through all the previous checks, the
help to provide a bit of protection from shrap- firearm should have proven itself to be func-
nel or burning propellant and hot gas. But if a tional and safe. If a round was fired with an ob-
firearm “grenades” during a test fire, some injury struction in the bore, the results would be cata-
may still occur. strophic, both to the firearm and to the opera-
tor. A small flash light can be used to examine
the bore, pointed from the muzzle and viewed
through the chamber.
The ammunition used in the test fire is also a
very important consideration. Because the am-
munition itself can be a cause for malfunction, it
is important to have multiple types of the same
caliber ready for testing. Only use caliber-cor-
rect factory ammunition and avoid using hand
loads and gun show reloads. If a client is report-
ing malfunctions with a specific type of am-
Figure 27: Examining the bore for obstructions. munition, ask them to provide you with a box
of rounds so that you can try to replicate the
malfunction. Never use customer-supplied hand
One final check of the firearm should be per- loads or loads you are unsure of when test firing.
formed before any test fire to ensure that it is One final consideration is your backstop or your
properly lubricated and there are no obstruc- bullet trap. You want to make sure you are test
tions in the bore. The action does not have to be firing into a backstop or trap that will handle the
cleaned, but there should be enough lubricant caliber that you are test firing. You also want to
for the firearm to properly function and to avoid make sure the backstop/trap can handle the rate
excessive parts wear. Verifying that the bore is of fire at which you may have to test the firearm.
clear of obstruction is extremely important. At Some public ranges have restrictions on specific

Figure 28: Caliber-correct factory ammunition.

28
 Figure 29: Appropriate backstops.

calibers and ammunition types or may not allow firearm as it fires. The following is the sequence
rapid fire. Many bullet traps have caliber restric- of events leading up to pressing the trigger:
tions and because of design constraints may be • With the muzzle pointed at a backstop
difficult or dangerous to try to rapid fire with. or inside a trap, insert only one cartridge
Public and private land (with permission) is into the chamber (single-shot) or feeding
more versatile and can often accommodate both device (repeater). Do not use more than
your test fire and sight/optic zeroing needs. one round with repeating and semi-auto-
Now that your safety gear, firearm, ammunition, matic firearms to lessen the risk of dam-
and backstop are prepared, it is time to test fire. age or injury if something goes wrong
There are certain things you should be watch- with the first round.
ing, feeling, and listening for while the firearm is
discharging and cycling. This may be difficult at • With single-shot firearms, close and lock
first, but over time, the more firearm types you the action. With repeating firearms, cycle
test fire, the more you will be able to examine the the action to feed the round. With semi-
automatic firearms, verify that the action/

29
 recoil spring has driven the action to feed If you are test firing a single-shot firearm and
and lock the round in the chamber. the test fire was successful, you do not have to
test the firearm any further. If you are test firing
• Establish an appropriate stance and grip. a repeating firearm, you will have to fire several
Secure handguns with both hands and more rounds. The next test will vary depending
rifles and shotguns with both hands and on action type, but will also mimic the first test.
the shoulder. For double-barrel break-action firearms:
• Deactivate the safety or set the selector • Load a cartridge into both chambers and
to fire. close and lock the action.

• Slowly and consistently press the trigger • Depending on action type, one of many
until the firearm fires. things may happen. Some action types
will allow you to simply deactivate the
• The firearm should have discharged, and safety and fire two barrels with two
the bullet should have completely exited separate triggers, in whatever order you
the muzzle. With semi-automatic ac- choose. Other action types will utilize
tions, the empty cartridge case should a double-set, single trigger that will fire
have been extracted and ejected several both barrels (one at a time) by pressing
feet. Some semi-automatic actions may the trigger twice. Depending on make and
lock open automatically because the model, the sequence of the barrel’s firing
magazine is empty. may be fixed or selectable. Regardless of
• With repeating manual actions, you will action type, deactivate the safety.
have to manually cycle the action to ex- • With double triggers, press one trigger
tract and eject the empty case. The case at a time and fire both barrels. With
should come out easily with no resistance.

Figure 30: Test firing.

30
 Figure 31: Test firing double-barrel break-action firearms.

double-set, single triggers, press the For repeating, manual action firearms:
trigger to fire the first barrel. Allow the • Load two rounds into the feeding device,
trigger to completely reset and fire the fixed or removable.
second barrel.
• Manually cycle the action to feed the
• Open the action. Both cases should lift first cartridge.
simultaneously as the action pivots open,
and with some actions, ejects automati- • Press the trigger and fire the first
cally. If the cases do not eject automati- cartridge.
cally, extract the cases by hand. Both
cases should come out easily with no • Release the trigger and manually cycle
resistance. If you are testing a double-set, the action to extract and eject the first
single trigger action with a fixed firing case and feed and chamber the second
sequence and the test fire was successful, cartridge.
you do not have to test the firearm any • Press the trigger once more and fire the
further. If you are testing a double trigger second round.
or double-set, single trigger action with a
selectable firing sequence, you will need • Release the trigger and manually cycle
to perform this test once more, firing the the action to extract and eject the second
barrels in the opposite order of the first case. Both cartridges should have fired
test. If the test fire was successful, you do and both cases extracted and ejected with
not have to test the firearm any further. ease. If the feeding device is capable of
holding more than two rounds, you will

31
 have to test the firearm once more. Load • The action should have automatically
the feeding device to capacity and per- cycled once more, extracting and ejecting
form the test once more. If the test fire the empty case and feeding the second
was successful, you do not have to test cartridge. Release the trigger and allow
the firearm any further. the FCG to reset. Depending on the
specific make and model, the action may
For semi-automatic firearms: be locked open. If the feeding device
• Load two rounds into the magazine and is capable of holding more than two
insert the magazine into the firearm. rounds, you will have to test the firearm
once more. Load the feeding device to
• Cycle the action to chamber the first capacity and perform the test once more.
round. If the test fire was successful, you do not
• Press the trigger and fire the first round. have to test the firearm any further.

• The action should have automatically Assuming all of the tests went smoothly and
cycled, extracting and ejecting the empty there were no malfunctions, the firearm does
case and feeding the second cartridge. not need to be tested any further. If at any point
Release the trigger and allow the FCG in the test fire the firearm malfunctions, you will
to reset. Check the action to verify that it need to diagnose the problem.
locked on the second cartridge. Now that you understand how many differ-
ent firearms are supposed to function, you can
• Press the trigger and fire the second begin to troubleshoot what is happening when
round. they malfunction.

Figure 32: Test firing semi-automatic firearms.

32
NOTES
NOTES
 Chapter 2 - Troubleshooting Break- and Bolt-Action Firearms
TROUBLESHOOTING FIREARMS 37
Ammunition-Induced Malfunctions 38
Operator-Induced Malfunctions 41
TROUBLESHOOTING BREAK- AND BOLT-ACTIONS 45
Break-Action Firearms 45
BOLT-ACTION FIREARMS 55
Break- and Bolt-Action Troubleshooting 65
Figure 1: Troubleshooting firearms.

Troubleshooting
Firearms
Troubleshooting firearms can be a simple task or
a frustrating endeavor, depending on the action
type. There are three basic factors to consider
when troubleshooting any firearm: the firearm,
ammunition, and operator. Even the fired cases
can provide evidence of what is happening in-
side the chamber.
If at any point during the previous test fire the
firearm malfunctioned, there are several areas of
the action to examine and questions you must
ask yourself. The same questions apply to a

37
client-supplied firearm that they say is malfunc- front of you so that you can try to diagnose any
tioning. These questions include, but are not operator error. This is not as easy if you are hav-
limited to: ing the firearm shipped from out of state.
• What type of malfunction was it — The first step in the troubleshooting process is
failure to feed, fire, extract, eject? to ensure the firearm is in proper working order
and safe to fire once again. Because you may not
• For failure to feed malfunctions, where have been present when the malfunction oc-
did the cartridge become stuck? Was curred or you are unsure of the condition of the
the round still in the feeding device, or parts after a malfunction, you should always do
wedged in the action or chamber? Did a quick safety and function check to avoid mag-
the round fail to seat completely or did nifying any issue. Verify that the bore is clear of
the action fail to lock? any obstructions and that the action still moves
• For failure to fire malfunctions, is there smoothly and freely. Perform a quick inspection
an indentation on the primer? What to verify that no parts are broken or damaged.
type of ammunition are you using? Are The next step is to try to recreate the malfunc-
you having the same issue with different tion. Using the same ammunition and trying to
types of ammunition? recreate the same conditions, did the same mal-
function occur? Did a similar malfunction oc-
• For failure to extract malfunctions, where cur? If you are able to recreate the malfunction,
is the empty case stuck? Did the case ex- then it will be easier to diagnose the problem. If
tract after a second or multiple attempts you are not able to do so, the original malfunc-
hand cycling the action? Does the rim of tion may have been a fluke or may have been
the case appear to be damaged, or does caused by operator error. With so many factors
the body of the case look scratched or involved, at some point over time you are going
scored? What type of grip and stance are to experience a malfunction that may only occur
being employed? once with no explanation.
• For failure to eject malfunctions, what If you are able to recreate the malfunction, you
type of grip and stance are being em- can begin the troubleshooting process. To make
ployed? What type of ammunition are the process simpler, you will need to eliminate
you using? Are you having the same issue as many factors as possible. The two factors that
with different types of ammunition? are the simplest to eliminate are ammunition
and the operator.
These questions are only the beginning of the
troubleshooting process. If you are the one ex-
AMMUNITION-INDUCED
periencing the malfunction or are present when
the malfunction is happening, it is much eas- MALFUNCTIONS
ier to diagnose what is happening than to try If ammunition is suspected of causing a mal-
to diagnose a client’s firearm sight unseen. To function, the simplest way of rectifying this is-
properly troubleshoot a client’s firearm, your sue is to use a different brand or type of am-
best chance is to try to replicate the malfunc- munition. If the malfunction is caused by a spe-
tion. This means they will need to provide you cific ammunition type, the malfunctions should
with some of the ammunition that the firearm cease when a different type of ammunition is
is malfunctioning with, and possibly some of used. If the issue persists, there is a possibility
the fired cases. If the client is local, when they that the malfunctions are caused by the firearm
come to drop the firearm off, you can request or by the operator.
that they demonstrate their grip and stance in

38
 Figure 2: Hollow point feeding malfunction.

There are several reasons why ammunition contribute to fail to feed malfunctions and are
would cause a malfunction. The first reason, fairly rare because of these factors.
which will lead to feeding malfunctions, is the Moving through the cycle of operations, ammu-
shape of the bullet. While standard “ball” am- nition can also be the cause of a failure to fire.
munition should feed through every action type, There are two basic reasons why ammunition
many will have trouble reliably feeding and cy- would fail to fire: improper storage and primer
cling hollow points (Figure 2) and wadcutters. alloy. Ammunition needs to be stored in a cool,
The issue occurs when the point (meplat) of the dry environment. Failure to properly store am-
bullet catches an edge and comes to a halt. The munition can lead to deterioration of both the
leading edge of the mouth of the hollow point propellant and priming compound. Either the
will typically catch on the leading edge of the primer will fail to ignite when struck by the
throat of the chamber or the leading edge of firing pin/striker, or the propellant will fail
the feed ramp. to ignite when embers from the primer travel
Even some ball ammunition with certain ogive through the flash hole.
lengths and shapes (Figure 3) may create mal- Improper storage can also lead to a dangerous
functions with some firearms. As the ogive of situation known as a squib load. A squib occurs
the bullet slides up the feed ramp or the mouth when only a portion of the propellant ignites,
of the barrel, its shape will drive the tip upward creating enough pressure to force the bullet from
into the top of the chamber and cause the round the case, but not enough to force it through the
to halt. The angle of the feed ramp/chamber bore. The bullet becomes lodged in the bore. If
mouth bevel and the shape of the ogive both a subsequent round were to be chambered and

39
 Figure 3: Fail to feed malfunction caused by a unique ogive shape.

fired, the stuck bullet would act as a cork, block- ammo, like a 7.62x51 NATO round in a .308
ing the bore and causing a huge pressure spike. Winchester chamber, there is a potential for a
The huge spike is enough to blow the action, “light strike.” A light strike occurs when the fir-
chamber, and barrel apart and cause severe in- ing pin or striker does not have enough energy
jury to the operator. to ignite the priming compound.
The second reason why ammunition may cause Ammunition can also cause both failures to
a failure to fire is the type of brass alloy used extract and eject. These malfunctions can be
for the primer cup. Ammunition designed for caused by the cartridge case’s material, coating,
military use typically utilizes a primer cup al- or the load of the round itself. Starting with fail-
loy that is harder than commercial ammunition. ures to extract, both the case material and its
This is designed to prevent a condition known (possible) coating can contribute to these types
as a “slam fire.” Many military firearms em- of malfunctions. While a standard brass case
ploy a “floating” firing pin, which means that it will expand and contract when fired, allowing
moves freely in its housing and is not restrained for easy extraction, cases made from steel will
by a return spring. If soft primer ammunition not always contract to their original size. The
is used in these firearms, there is a chance with increased friction from the swollen case against
the energy of the firing pin slamming forward the chamber walls will place more tension on
that the round may fire. If hard primer ammuni- the extractor than it can handle. When the ex-
tion is used in firearms designed for commercial tractor tries to pull against the case head, the

40
 Figure 4: Military vs. commercial ammunition.

friction on the case will overcome the power of

the extractor and the extractor’s claw will slip
over the rim.
Case coatings can also lead to the same type of
failure to extract malfunctions. Typically, steel
case ammunition is coated with either lacquer
or polymer. During rapid fire strings, the heat Figure 5: Steel-cased, lacquer-coated ammunition.
inside the chamber is great enough to soften and
melt the case coating. With enough rounds fired,
the coating will begin to “gum up” the chamber OPERATOR-INDUCED
and cases will begin to stick. If left untreated,
even brass cases will begin to stick to the lacquer
MALFUNCTIONS
or polymer remnants inside the chamber. Once you have ruled out ammunition as a
With semi-automatic firearms, the specific possible cause of malfunction, the next factor
“load” of the cartridge can cause both failure to that can be easily ruled out is operator error.
extract and eject malfunctions. Because the func- Operator-induced malfunctions can typically
tion of semi-automatic firearms is reliant on the be ruled out during the initial test fire. Semi-
pressure generated by the cartridge, rounds that automatic firearms are the most susceptible to
are underpowered may not fully cycle the action. operator error, with semi-automatic pistols top-
Ammunition designed for self-defense or mar- ping the list. Certain manual actions, such as
keted as “low recoil” target ammunition, or am- lever- or pump-actions, can also be affected by
munition that was improperly stored, may all fail improper technique.
to generate enough energy to fully cycle the ac- Operator error can lead to failures to feed, ex-
tion and cause either a failure to extract or a fail- tract, and eject. Most operator error is caused
ure to eject. The round may even generate enough by short-stroking the action due to a condi-
energy to extract and eject the empty case, but tion known as “limp wristing.” Limp wristing
not to feed or fully chamber the next round. This is a term that describes an improper shooting
condition is known as “short-stroking.” technique where the (semi-automatic) firearm

41
 Figure 6: Limp wristing.

is not secured while being discharged. The en- is not fully seated, when the action is
ergy used to cycle the action is transferred to cycled the bolt/slide will simply pass
the whole firearm as it recoils rearward and dis- over the top round and fail to feed. The
sipates. This causes the action to short-stroke. magazine may even fall from the action
With manual repeating actions, the malfunction when it is cycled. When fully seated,
is created when the operator manually short- the magazine should “click” into place.
strokes the action. Operator error can easily be Sometimes, when a magazine is loaded
averted by securing the firearm and utilizing to its maximum capacity, it will not seat
proper shooting technique. when the bolt or slide is closed. You may
There are many other types of shooter-induced have to download the magazine one to
stoppages that you may find on a case-by-case two rounds so that the magazine will
basis. These malfunctions can be attributed to fully seat.
inexperience and can be resolved with proper • Depressing the Magazine Release
technique. The malfunctions include but are not While Firing – Depressing the maga-
limited to: zine release while firing will lead to a
• Failure to Disengage the Safety – (perceived) failure to fire, but the cham-
Failure to disengage the safety will lead ber is actually empty. This issue is caused
to a (perceived) failure to fire. Depending by an improper grip. When the opera-
on the action type, the trigger may be tor places his/her hands on the firearm,
blocked and not move, or move with a an improper grip can lead to part of
“dead” feeling. the hand contacting the magazine re-
lease under recoil. This would cause the
• Failure to Seat the Magazine – Failure magazine to drop slightly and the bolt/
to fully seat a magazine will lead to a slide to pass over the next round. Simply
(perceived) failure to fire, but the cham- changing the shooting grip will resolve
ber is actually empty. If the magazine this issue.

42
• Engaging the Bolt/Slide Stop While Now that you have ruled out ammunition and
Firing – Engaging the bolt/slide stop operator error as possible causes of malfunction,
while firing will lead to a (perceived) you can focus on the firearm. Each action type
empty magazine. Like the previous will require understanding of the functions of
malfunction, this malfunction is caused operations for each type to be able to effective-
by improper grip. When the operator ly troubleshoot. Each action type will feature
places his/her hands on the firearm, an unique factors as to why a specific malfunction
improper grip can lead to part of the occurred. The following is a detailed overview
hand contacting the bolt/slide stop under of the causes for various malfunctions in differ-
recoil. This would cause the bolt/slide to ent action types.
lock open as if the magazine were empty.
Simply changing the shooting grip will
resolve this issue.

• Short-Stroking the Trigger – Short-

stroking the trigger will lead to a (per-
ceived) failure to fire. If the trigger is not
allowed to fully reset, it may feel “dead” or
light when pressed again. Simply allow-
ing the trigger to return to its resting po-
sition until you can feel or hear (or both)
the trigger reset will resolve this issue.

43
THIS PAGE INTENTIONALLY BLANK

44
 of operations are not performed by the action;
Troubleshooting they are performed manually by the operator.
Typically, the break-style action will only fire
Break- and Bolt- and partially extract, while some actions may
even eject. This makes diagnosing these action
Actions types fairly simple.

Break-Action Feeding Problems

Of all of the action types, including many of the We will begin with failure to feed malfunctions.
manual actions, the break- and bolt-actions are Because the feeding step is controlled entirely
some of the simplest designs. With less moving by the operator, there are only a few things that
parts, the chances of malfunction are reduced, can cause a feeding malfunction with break-
which also means there are less parts to diag- action firearms. Starting with the mouth of the
nose. As long as you have a basic understanding chamber, if there are any burrs or the mouth was
of how these actions operate, troubleshooting not properly chamfered/beveled, the round can
should be straightforward. snag or become stuck against the inside lead-
ing edge of the chamber. You may notice scoring
BREAK-ACTION FIREARMS along the side of the case (or snap cap) from the
burrs on the chamber mouth.
Of the two action types (break and bolt), the
The next possible cause for a feeding malfunc-
break-action is probably one of the simplest de-
tion in a break-action firearm would be dirt and
signs. In fact, several of the steps of the cycle
debris. Neglecting basic cleaning and mainte-
nance can lead to a situation where excessive
dirt and debris buildup inside the chamber can
create a failure to feed malfunction. Firearms
that are stored with excessive oil can also lead to
malfunctions. Over time, the oil in the chamber
will begin to gum up and become sticky, making
loading difficult. Using more oil to try to remedy
the issue will only compound the problem. The
oil will attract more dirt and debris and will even-
tually become mud-like and eventually harden.
The least likely cause (but still a possibility) is a
roughly machined chamber. If the tooling used
to cut the chamber is old or dull, or is not mov-
ing at the correct speed, it will leave the sur-
face finish of the chamber “chattered” or rough.
The machining in the chamber would have to
be very rough, featuring scratches and scoring
before it could create a failure to feed, but it is
possible. An undersized or out-of-spec chamber
can also lead to a feeding malfunction.
Repairing most of these issues is straightfor-
ward. If the mouth of the chamber is burred or
the leading edge has not been beveled or cham-
Figure 7: Leading edge of a break-action chamber. fered, you will need to clean up the edge. This
can be easily accomplished with some needle

45
 brush and applying cleaner before the chamber
is completely clean. Once the chamber is clean,
apply a light coating of a quality firearm lubri-
cant. Do not apply the lubricant too heavily as it
will lead to the same problem. Regular mainte-
nance will prevent these issues from returning.
If the chamber is rough or undersized, the fix
is a bit more difficult. Starting with a rough
chamber, the scratches, scoring, and some of
the chatter can be polished out. If you have ac-
cess to a lathe and are able to remove the bar-
rel from the action, you can repair the chamber
with a marginal amount of effort. Once you
have the barrel aligned and secured in the chuck
of the lathe, you can use a wooden dowel (with
Figure 8: Cutting the chamfer with a half-round file. a smaller diameter than the chamber) and a
piece of sandpaper to polish out the scratches
or chatter. Using 400-grit sandpaper wrapped
around the dowel, apply light pressure to the
or diamond files and several different grits of wall of the chamber while the barrel spins. You
sandpaper. If the edge is just burred, you must only want to remove the scratches and (some) of
simply remove the burr with a small file until the chatter, as removing too much material can
all the burrs are gone. Make certain you follow lead to an oversized chamber that is dangerous.
the shape of the current bevel or chamfer. Once Lightly sand the chamber with 400-grit until
the burr has been removed, lightly sand the area the scratches are gone and finish the chamber
with 150-, 220-, and 320-grit sandpaper, re- with 800-grit sandpaper to apply a quick pol-
spectively, to smooth out any file marks. ish. Remove the barrel from the lathe and thor-
If the mouth of the chamber was not chamfered, oughly clean and lightly lubricate the chamber.
you will need to profile the inside edge. Using a Re-install the barrel and test fire the firearm to
half-round needle file, bevel the inside edge of verify function.
the mouth of the chamber. Cut the chamfer at If you do not have access to a lathe, or you are
(or near) a 45º angle, roughly .020 in. – .030 in. not able to remove the barrel from the action,
deep. The angle and size do not have to be exact there is another option. Brownells offers an al-
as long as the end result produces smooth feed- ternative in the form of their Flex-Hone® line
ing. Once the chamfer has been cut using files, of products, designed to polish a chamber while
clean the file marks up with 150-, 220-, 320-, the barrel is installed in the action. The Flex-
and 400-grit sandpaper, respectively. Hone tool features a head that is roughly the
Fixing feeding malfunctions caused by a dirty same size and shape (or slightly oversized) as
chamber is as simple as cleaning the chamber. the chamber, made up of small abrasive (silicon
Using a brass chamber brush and a quality clean- carbide) balls that are used to polish. The head
ing solvent, thoroughly scrub the chamber until is attached to a long shaft that is attached to
it is clean. You may have to use specialized clean- and driven by a hand drill. You must use only
ers designed to remove carbon, copper, and lead Flex-Hone oil when using the Flex-Hone tool
fouling if the firearm has been heavily used while system to polish the chamber. The Flex-Hone
maintenance has been neglected. You may have tools typically come in both 400- and 800-grits.
to perform several cycles of scrubbing with the

46
 Figure 9: Repairing a rough chamber in a lathe.

With the Flex-Hone tool (Figure 10) attached

to the hand drill, apply the Flex-Hone oil to
both the Flex-Hone tool and the chamber.
Using medium speed and light pressure, polish
the chamber, starting with the 400-grit first. You
only want to remove the scratches and (some)
of the chatter, as removing too much material
can lead to an oversized chamber that is dan-
gerous. Follow the 400-grit with the 800-grit
Flex-Hone tool and finish by thoroughly clean-
ing the chamber and bore and lightly oiling Figure 10: Brownells Flex-Hone tool. Image courtesy of
both with a quality firearm lubricant. Once ev- Brownells.
erything is clean and oiled, you can reassemble
the firearm and test fire it. If the issue persists
after polishing the chamber, you may need to barrel(s) needs to be removed from the action.
rebarrel the firearm. Increasing the dimensions Using a specialized chamber reamer, called a
of the chamber too far can create a very danger- finish reamer, cut the chamber to length. Finish
ous (headspace) issue. reamers are produced for use by both lathe and
If the feed issue is a result of a “short” cham- hand. Reamers intended for hand use typically
ber, you will need to recut the chamber until feature an integral pilot used to keep the reamer
it is within specification. This can be accom- centered in the chamber. Reamers intended for
plished on a lathe or by hand; either way, the lathe use do not typically feature this pilot as the

47
alignment of the cutter and chamber is accom- engaged locking lugs on the receiver and the two
plished through adjustments on the machine. parts are secured by the top lever assembly or the
Whichever method you employ, make certain crossbolt. Depending on design, the breech will
to use plenty of cutting oil and move slowly. either lock when the locking lugs located in the
Depending on how far you need to cut the receiver are secured by the top lever, or when the
chamber, remove only a few thousandths (.001 crossbolt engages the cutout in the barrel’s lock-
in. – .005 in.) of material at a time. Check the ing lug. When the top lever is manipulated and
chamber with a Go gauge often until the cham- the breech is unlocked, the locking lugs in the
ber is cut to full depth. Do not cut the chamber receiver will disengage the lugs on the barrel(s)
too long as it will lead to a very dangerous head- and allow the barrel to pivot down and expose
space issue. Once the chamber is cut to length, the chambers.
reinstall the barrel(s) back in the action, check Much of the physical process of locking is con-
headspace, and test fire the firearm. trolled by the top lever or crossbolt, while the
Break-Action Locking Problems locking lugs secure the chamber during dis-
charge. If the top lever assembly/crossbolt is
Moving through the cycle of operations, the damaged or broken, there is a possibility that
next types of malfunctions you may experience the breech can unlock and open during firing,
would occur during the locking step. The lock- which can lead to damage to the firearm and in-
up of the barrel(s) and receiver is critical to the jury to the operator. Although the breech com-
proper function of the firearm and the safety of ing unlocked during discharge is fairly uncom-
the operator. When the breech of a break-action mon, broken parts, damage, and excessive wear
firearm is locked, locking lugs on the barrel have can all lead to a locking/unlocking malfunction.

Figure 11: Locking surfaces of break-action firearms.

48
 Figure 12: Peening the locking lugs and hinge pin recess.

Excessive wear of the locking lugs and hinge If the action is “loose,” you can replace the
can also create an excessive amount of “play” be- hinge pin or peen the locking surface to remove
tween the receiver and barrel(s), which can lead some play. Peening is a process of working
to a dangerous situation. metal with the domed end of a ball-peen ham-
Repairing locking issues is fairly straightfor- mer. Peening is used to remove metal, as well
ward, depending on the cause of the malfunc- as harden the surface of a part, like with shot
tion. If the action fails to lock because of dings peening. Peening with a ball-peen hammer will
or burrs on the locking surfaces, you can remove leave small dish-shaped indentations on the
and repair the parts by filing the burrs off or by metal’s surface, while the material around the
filing down the raised portion of the ding until it dish will be forced outward.
is flush with the surface. Once the burr or ding is Peening the locking and pivot surfaces of a
removed, clean up the file marks with sandpaper break-action barrel will force material into ar-
in 150-, 220- and 320-grits. Be cautious not to eas where material has been worn down, restor-
remove any more material than necessary. ing some of the tolerance lost. Peening can help
If the lugs on the barrel are damaged or broken to alleviate both vertical and horizontal play.
or if any of the parts of the locking assembly lo- Vertical play is typically controlled by peening
cated in the receiver are damaged or broken, you the locking lugs, while horizontal play is con-
will have to replace these parts. You can typi- trolled by peening the pivot pin recess surfaces.
cally find factory replacement, new aftermarket, Peening can be accomplished with a ball-peen
or slightly used parts to replace the broken or hammer or with modified center punches. You
damaged ones. Once the part(s) has been re- will also need a flat metal backing to perform the
placed, perform a function and safety check to peening against because wood and plastic have
verify the function of the firearm. too much “give” and will absorb impact instead

49
of transferring it. Place the barrel(s) on the met- If there is still some vertical play, you will need
al backing so that only the lugs and pivot recess to peen the locking lug(s). You will need to peen
are supported and nothing is touching the bar- the lug(s) in such a way that the redistributed
rels. If the barrels are not allowed to float, there material forces the barrels downward. Typically,
is a chance they can be damaged when peening this involves peening the lug along its inside top
the lugs. Make sure the barrels are stable and edge. This will force material upward and the
secure before beginning. barrels downward during lockup. Make sure to
To begin, you will want to remove the fore and peen both sides of the lug(s) evenly and spaced
aft play, which is controlled by the recess for at least ⅛ in. from the edge. Begin from the in-
the hinge pin. You will want to peen the semi- side corner of the lug(s) and work outward to-
circular recess around its circumference, about ward the edge. Peen a small area and reinstall
1/16 in. to 3/32 in. from the edge. Do not peen the the barrel(s) to check fitment. If the lugs are too
edge of the recess to prevent damage or chip- tight or the pivot recess is too tight, you can re-
ping the edge. Begin in the center of the arc and move a small amount of material with a file and
peen outward along the radius. Do not peen the clean up file marks with sandpaper.
entire radius; rather, peen a small section in the Break-Action Cocking Problems
center and turn the barrels over to perform the
same exact peening on the opposite side. Make Continuing through the cycle of operations, the
sure both sides are even. Reinstall the barrels next type of malfunction you may experience
and test the fit. Often, peening the pivot pin would occur during the cocking step. Failures
recess will remove both horizontal and vertical to cock occur when the hammer/striker(s) fails
play.

Figure 13: Break-action sear/hammer engagement assembly.

50
to engage the cocked position. Depending on Occasionally, new or replacement parts are not
the specific model, the hammer(s)/striker(s) is available, but sometimes worn sear surfaces can
cocked by a cocking bar/lever (which automati- be saved by simply “dressing” or slightly reshap-
cally sets the safety) or manually by the opera- ing the existing parts. If the sear(s) is rounded
tor once the breech has been locked. Failure or set at a negative angle, it can sometimes be
to cock malfunctions can render the firearm shaped using various grits of stone files. Refer
inoperable and (depending on cause) can lead to the drawing on page 22 (Figure 20) of correct
to a dangerous situation known as hammer fol- and incorrect sear angles previously in this guide.
low. Hammer follow occurs when the hammer/ This process is often tedious and very slow be-
striker fails to engage the sear surface that holds cause you must remove the part(s), lightly shape
it in the cocked position. This allows the ham- the sear faces, reinstall the parts, and function
mer to fall prematurely and possibly cause an check the assembly. The process is repeated sev-
accidental discharge. eral times until the function is correct.
Failure to cock malfunctions are typically caused Use a magnifying tool (preferably a magnified
by a damaged or worn cocking bar/lever(s) and lamp) to examine the sear engagement angles
its assemblies or incorrectly shaped sear surfac- while the parts are installed, if possible. If not,
es. They can also be caused by worn or damaged use marking fluid or a Sharpie® to reveal where
springs. If the cocking bar/lever is damaged or the surfaces are contacting. Pay special attention
broken, it will fail to push the hammer/striker(s) to the relationship of the sear angle to the di-
back far enough to fully engage the cocking rection of travel of the assemblies, as the sear
sears. If the sear surface (either on the hammer/ surfaces shear across each other. Even if the sear
striker or sear assembly) is damaged, rounded or surfaces are set at a positive or neutral angle to
worn, the hammer/striker may slightly engage each other, they may be set at an incorrect angle
the sear and slip off or push the sear out of the in relation to their travel.
way. If the springs are worn or damaged, they
may fail to push the sear assembly into the ham-
mer/striker’s path and allow the hammer to fall.
A damaged or broken hammer strut can also
prevent the hammers from traveling backward
far enough to fully engage the sear(s). Excessive
dirt and debris can also cause these assemblies
to malfunction.
Repairing failure to cock malfunctions is as sim-
ple as replacing the worn or damaged parts. This
means the cocking bar/lever and assembly or the
FCG assembly. Typically, you will want to replace
both hammer/striker and sear assemblies as well
as springs to completely “refresh” the FCG. You
can replace the worn or damaged parts, but you
will be ensuring that sometime in the near fu-
ture you will be replacing additional parts. Often,
then-new parts will put strain against the old Figure 14: Stoning sear surfaces.
parts and cause them to expire prematurely.

51
Lightly stone the sear surface(s) with an India
stone (roughest) to shape the facets until they
are the correct angle in relation to their travel.
Move slowly and be cautious not to remove
too much material at a time. With only a few
strokes of the stone file, reapply marking fluid
and reinstall and function check the assembly.
Make sure to hold the stone steadily, at the cor-
rect angle for each stroke. Do not wobble or
vary in your form as you shape the sear faces.
Once the facets are shaped, you can clean the
file marks up with a black or white ceramic
stone file. Clean and reinstall the parts and per-
form a function and safety check. Reassemble
the firearm and test fire. If everything performs
as it should, you are done. If not, you will need
to repeat the process. Please note that you can
only file sear surfaces so far before you start to
affect their safe function. Use your experience
(and discretion) to realize when a part cannot
be saved and another option must be utilized.

Break-Action Failure to Fire

The next types of malfunctions you may expe-
rience would be failures to fire (FTF). Failures
to fire occur when the firearm’s FCG fails to Figure 15: Parts of a break-action extractor.
generate enough energy to ignite the cartridge’s
primer. With break-actions, this can be caused
by several parts of the FCG. Depending on the being discharged, like with function checks and
specific model, a failure to fire can be caused by dry fire practice. Excessive dirt and debris can
the hammer(s), striker(s), fining pin(s), transfer also slow parts of the FCG down enough to
bars, selectors, or springs. Any of these parts limit their potential energy.
can contribute to a condition known as a “light If a failure to fire malfunction occurs and there is
strike.” A light strike occurs when the primer is no mark on the primer cup, there is a high possi-
impacted but not ignited. Often, there is a small bility that the tip of the firing pin/striker is bro-
indentation on the primer cup. ken. The firing pin or striker may be broken far-
Damage, wear, dirt, and debris, and parts break- ther down the part’s body, or other parts may be
age can all lead to failure to fire malfunctions. broken, like the hammer or transfer bar (which
Often the leading cause of FTF malfunctions transfers energy from the hammer(s) to floating
is worn springs that fail to drive the firing pin/ firing pin(s)). These parts may become wedged
striker fast enough to generate the required in the FCG or in other parts of the action.
amount of energy needed to properly crush the Repairing failure to fire malfunctions is as sim-
primer cup. FCG springs will typically wear ple as cleaning the FCG or replacing the worn
faster than other firearm springs because they or damaged parts. This means the hammer(s),
are under strain even when the firearm is not striker(s), firing pin(s), the transfer bar and

52
springs. Typically, you will want to replace both work with the barrels still attached. Once you
hammer/striker and sear assemblies as well as disassemble most of the action and remove the
springs to completely “refresh” the FCG. You broken assemblies, you will be able to unlock the
can replace the worn or damaged parts, but you action once again. Once the action is open and
will be ensuring that sometime in the near future the broken parts have been replaced, you can re-
you will be replacing additional parts. Often, assemble the firearm normally and test function.
then-new parts will put strain against the old
parts and cause them to expire prematurely. Break-Action Extracting Problems
Continuing through the COO, the next types of
Unlocking Problems malfunctions you may experience are failures to
Moving through the cycle of operations (COO), extract. A failure to extract occurs when the ac-
the next types of malfunctions that may occur tion pivots open and the empty case(s) remains
would be during the unlocking step. Although in the chamber. Both the extractor(s) and the
this scenario is uncommon, there is a possibil- assemblies and the chamber can contribute to
ity that parts of the action that control locking failure to extract malfunctions in break-actions.
can break and cause the action to remain locked. When the action is opened, a bar/lever located
The top lever and locking assemblies inside the in the barrel(s) acts against a lug/protrusion on
receiver can both cause this type of malfunction the receiver, which drives the extractor(s) out-
if they were to break inside the action. ward, forcing the cases from the chamber.
Repairing unlocking issues is as simple as replac- When a failure to extract malfunction occurs,
ing the broken parts. The most difficult aspect either the extractor (or its assembly) has failed
of the repair is that you will not be able to field or the chamber is excessively dirty or rough. If
strip the firearm, which means you will have to the extractor or its assembly is broken, damaged

Figure 16: Auto-ejecting break-action shotgun.

53
 Figure 17: Single-shot, fixed, and detachable box magazine bolt-actions.

or worn, the extractor will not drive the case or extractor/ejector will begin to extract the spent
will slip over the case rim. If the chamber is ex- cases from the chamber. When the action reach-
cessively dirty or rough, the case will stick to the es a certain point in its travel, the spring driving
chamber and cause the extractor to jump over the extractor/ejector will release its energy, driv-
the case rim. ing the ejector outward and sending the empty
If the failure to extract is caused by the extractor cases flying.
or its assembly, you can simply replace the dam- Failure to eject malfunctions occur when any
aged or worn parts to remedy the issue. If the part of the auto-eject assembly becomes worn,
failure to extract is caused by a rough chamber, damaged, or broken. When these parts or as-
the fix is a bit more involved. Repairing a rough semblies fail, the empty cases will remain in the
chamber can be accomplished on a lathe with chamber. Although this is not a big deal with
sandpaper and a dowel, or with Brownells Flex- the break-action design, the firearm is still mal-
Hone line of products. functioning because it is not operating normal-
ly. The empty cases can still be removed from
Failure to Eject Problems the chambers by hand, like with other break-
The final types of malfunctions you may en- action designs.
counter with break-action firearms are failures Repairing failure to eject malfunctions with
to extract. Typically, break-action firearms do certain break-action firearms is as simple as re-
not automatically eject empty cases like other placing broken, damaged, or worn parts. This
action designs, but some “high-end” break-ac- includes the extractor/ejector, its assembly, in-
tion firearms feature a type of auto-eject feature. cluding tripping mechanism, and spring. Once
The auto-eject feature utilizes a spring-loaded the assemblies are replaced, function check and
extractor that also acts as an ejector. When test fire the firearm.
the action is opened and begins to pivot, the

54
 This limits the number of assemblies and parts
Bolt-Action Firearms that can affect the feeding step in the cycle of
operations. The part that affects the reliability of
the feeding process is the breech end of the bar-
Like break-action firearms, bolt-action firearms rel, more specifically the mouth of the chamber.
are also very simple machines. Depending on The bevel or chamfer on the leading edge of
the specific model of bolt-action firearm, some the mouth of the chamber makes the cartridge’s
of the steps of the COO are not even controlled transition into the chamber. If there is no bevel
by the firearm. Bolt-action firearms are available or chamfer present, it is extremely likely that the
in both single-shot and repeating actions. The point or nose (meplat) of the bullet will catch the
addition of a feeding device will add a new fac- leading edge of the chamber and jam in the ac-
tor to diagnosing certain bolt-action firearms. tion. A roughly machined, short, or excessively
We will begin with failure to feed malfunctions. dirty chamber can also cause feeding issues. One
The cause of the failure to feed will depend on other possible cause could come from a worn or
the specific action types, which are divided into damaged bolt face that pushes the cartridge off-
single-shot and repeating firearms. Repeating center and cants it enough to cause a malfunction.
bolt-actions are even divided into fixed (internal Repairing feeding issues with single-shot bolt-
blind box) and detachable magazine types and action firearms is fairly straightforward. If the
by the actual feed process, controlled or push issue is caused by a lack of bevel/chamfer, you
feed. Each type will feature unique factors that will need to form a bevel on the chamber’s
can contribute to fail to feed malfunctions. mouth. The process is simplified if you have the
tools and experience to remove the barrel from
Single-Shot Bolt-Action the action. If not, you will have to cut the cham-
Feeding Problems fer in with the barrel installed in the receiver. If
Starting with single-shot, bolt-action firearms, the issue is caused by a short or rough chamber,
diagnosing feeding issues is fairly simple because you will need to polish or recut the chamber
half of the feeding process is accomplished by to SAAMI specs. If the bolt face is damaged
the operator, by hand. Once the operator inserts or worn, you will need to replace the bolt/bolt
a cartridge into the breech, he/she must manipu- head. If the chamber is excessively dirty, you will
late the bolt forward (feeding the cartridge into need to thoroughly clean and lightly lubricate
the chamber) and down (locking the chamber). the chamber.

Figure 18: Controlled vs. push feed systems.

55
Repeating Bolt-Action Feeding Problems (either integral to the magazine body or under-
Moving on to repeating bolt-action firearms, side of the receiver) hold the cartridges in the
diagnosing feeding issues can be a bit more magazine and align them with the chamber.
challenging with the added factor of the maga- The spring forces the follower upward, which
zine assembly. To make things even more chal- supports and drives the new cartridges in prepa-
lenging, you must understand the two differ- ration for feeding. The hinged floor plate allows
ent methods of feeding in certain bolt-action access to the magazine for maintenance or re-
designs: controlled and push feed. Additional pair and cannot be used for loading.
parts such as magazine catch/releases and mag- When the magazine has been loaded, the op-
azine cutoffs can also make diagnosing feeding erator can manipulate the bolt and begin to feed
issues in these firearms more difficult. the first round from the magazine. As the oper-
We will begin with internal (blind) box maga- ator drives the bolt forward, a lug or protrusion
zine-fed bolt-action firearms. Internal box-fed, on the underside of the bolt contacts the head
magazine-fed bolt-action firearms feature an of the cartridge case and begins to push the car-
integral box magazine that is concealed within tridge from the feed lip(s) of the magazine. This
the stock of the firearm, which is why it is often is where certain feed design types differ.
referred to as a “blind box” or blind magazine. With a controlled feed design, once the bolt
The magazine consists of a body (which may has pushed the cartridge clear of the feed lips,
be integral to the receiver), follower, spring and the head of the cartridge will move upward so
(sometimes) a hinged floor plate. Internal box that the extractor hook slides into the extractor
magazines can be found in both single- and groove on the case head. The cartridge will cen-
double-stack applications and in single- and ter itself on the bolt face, while the case is sup-
double-feed designs. The internal box magazine ported and aligned by the bolt. The bolt head will
is loaded by the operator, through the ejection continue to support the case head as the round is
port, and can typically hold between two and fed, seated, and locked into the chamber.
five cartridges. The feed lips of the magazine

Figure 19: Bolt-action magazine catch.

56
 Figure 20: Adjusting the feed lips to control feeding.

With a push feed design, once the bolt has for feeding. If the follower or feed lips are bent
pushed the cartridge clear of the feed lips, the or broken, the rounds will become misaligned
cartridge will continue forward, being driven by with the chamber and jam in the action. If the
the bolt face and leading face of the extractor. bolt face or extractor head/claw is worn or dam-
The bolt and extractor will continue to drive the aged, it can cause the round to cant as it is being
round forward until it feeds into the chamber and fed into the chamber. If the feed ramp or bar-
completely seats. Once the round is completely rel mouth are burred, damaged, or rough, it will
seated in the chamber, the extractor will move cause the round to slow or stall and jam. If the
over the rim of the case and into the extractor cutoff malfunctions, it can prevent the magazine
groove as the bolt continues forward and locks. from feeding new rounds.
Any one of these assemblies can contribute to a Repairing failure to feed malfunctions with in-
failure to feed malfunction, as well as other fac- ternal box magazine-fed firearms is as simple as
tors like a dirty, rough, or undersized chamber. replacing broken, worn, or damaged parts. This
There are some internal box magazine designs includes the parts of the magazine (body, fol-
that utilize a component called a magazine cut- lower, and spring) and the bolt. If the feed ramp
off or cartridge stop. The cutoff allows the oper- or chamber mouth is rough or burred, you can
ator to block off the cartridges in the magazine dress the parts with files and sandpaper. If the
and prevent them from feeding. This design al- chamber is rough or undersized, you can polish
lows the operator to change ammunition types or recut the chamber to SAAMI specs. If the
without unloading the magazine. This design chamber is excessively dirty, thoroughly clean
also allows some military bolt-action rifles to and lightly lubricate the chamber.
fire grenades with an adapter and blanks. Detachable box magazine-fed bolt-action fire-
If the magazine spring is worn or broken, it arms present a few additional factors to consider
will fail to force the follower and rounds up- when diagnosing the designs. The magazine
ward into the path of the bolt in preparation catch’s purpose is to hold the magazine in place

57
so that it is aligned perfectly in the action. If the receiver. The bolt should close and lock on a
catch was broken, damaged, or worn, it would cartridge smoothly with only slight resistance.
allow the magazine to shift its position in the re- You should never have to force the bolt closed.
ceiver and move the rounds out of line with the There are two assemblies that can affect the
bolt. If the catch is broken, damaged, or worn, locking step in the COO: the locking lugs lo-
replace the parts and perform a function check. cated on the bolt and receiver and the bolt han-
Unlike internal box magazines, the feed lips of dle. If the locking lugs are damaged or burred,
metal detachable box magazines can sometimes the lugs may not be able to fully engage or even
be reshaped or rebent to properly align the car- begin to engage. This includes the lugs located
tridge for feeding. Over time, the magazine body, on the bolt head or body and the lugs or lug re-
especially the feed lips, will experience hard use cesses located in the receiver. Typically, the bolt
and possible damage that may cause the feed handle will rest in a slot or cutout in the receiver,
lips to move and change the alignment of the or act as a backup or redundant locking lug, or
cartridge. Any change in the shape or spacing as the only locking lug (with low-power rimfire
of the feed lips will cause the tip of the bullet to cartridges). If the handle is bent, it may not fit
rise or dip beyond its point of alignment. into its recess and allow the action to fully lock.
If the forward portion of the feed lips are much Depending on how much damage the lugs bear
wider than the rear, the nose of the cartridge will or how far out of spec the bolt is bent, you may
rise and cause the cartridge to jam against the be able to repair the bolt/handle and spare the
inside top of the breech. If the forward portion expense of replacing them. If the lugs are only
of the feed lips are narrower than the rear, the burred or feature minor dings, you can dress
nose of the cartridge will dive and most likely them with files and sandpaper. If the issue is
jam against the front of the magazine body or with the lug located inside the receiver, you
into the feed ramp. The feed lips should be ad- may have trouble reaching the area of the lug
justed so that the tip of the cartridge is pointed with the barrel installed. If the lug(s) is seriously
straight into the chamber or slightly upward so damaged or broken, you will have to replace the
that it will ride up the feed ramp. bolt (head or body) or (worst case) the receiver.
Adjusting the feed lips is fairly simple and can be If the bolt handle is bent and preventing the ac-
accomplished using pliers or specialty forming tion from locking, you may be able to bend it
pliers available through Brownells. Make slight enough to allow the action to close and lock.
adjustments to the feed lips and make sure to Depending on how far out of spec the handle
adjust each side evenly. Perform a function check is, you may be able to bend it “cold” or you may
after each adjustment to verify the alignment of have to heat the handle up to bend it. Cold
the snap caps or dummy rounds. You may have bending is simply done by hand (at room tem-
to adjust both the front and the rear of the feed perature), with the bolt body secured in a vise.
lips to get the round in perfect alignment. Cold bending can only be done if the handle is
slightly out of spec. Trying to bend a bolt handle
Bolt-Action Locking Problems too far without heat will result in a cracked or
The next type of malfunction you may expe- broken bolt handle. With the bolt secured in a
rience with bolt-action firearms is a failure to vise, simply apply pressure by hand in the direc-
lock. A failure to lock occurs when the bolt is tion the handle needs to move in order for it to
manipulated, but doesn’t or can’t complete its function. Move slowly and check for fit often.
forward stroke so that the bolt’s locking lugs You only need to bend the handle enough to
fully engage the locking lugs located on the close and lock.

58
Figure 21: Bolt-action locking surfaces.

59
If the bolt handle is bent farther than can be
fixed cold, you may have to bend the handle
using heat, or you may have to just replace the
bolt body (or complete bolt). Depending on
how thick the bolt handle is and the point of
the bend, you may be able to use a propane or
MAP torch to get the handle hot enough. If
the handle is thicker, you will have to use an
oxy-acetylene torch to generate enough heat to
bend the handle. You will also need some type
of heat-blocking compound such as Brownells
Heat Stop™ heat control paste to protect the
bolt head and body from heat that may affect
their temper.
Begin by stripping the bolt of the firing pin and Figure 22: Brownells Heat Stop paste.
other assemblies (extractor or ejector). You will
have to get the bent area of the handle cherry
red to white hot (~1500º – 2300º+ Fahrenheit)
and you do not want any of that heat transferred
to the locking lugs (or cocking cam) and possi-
it backward and sets it in the cocked position.
bly softening (annealing) the hardened surfaces.
With the cock on closed designs, the bolt must
Heat the bent area evenly all the way around
be manipulated up and backward; it is not until
the handle and make sure the handle is hot
the bolt is driven forward that the cocking cam/
throughout the bend (its core). Once the handle
piece is captured by the FCG. As the bolt con-
has been bent, you will need to let it air cure and
tinues forward, the firing pin/striker is set to the
(once it is cool to the touch) clean it off so that
cocked position.
you can perform a function check. If the bolt
closes and locks, you are done. If not, you may Regardless of the design, failure to cock mal-
have to repeat the process. functions can only be cause by a few factors. If a
bolt-action rifle fails to cock, it is because either
Bolt-Action Cocking Problems the cocking cam’s/piece’s sear surfaces are worn
Moving through the cycle of operations, the or damaged or the sear surface in the remainder
next type of malfunction you may experience of the FCG is worn or damaged. There may also
with bolt-action firearms would be a failure to be a chance that the sear surfaces are set at an
cock. Most bolt-action rifles utilize a striker or incorrect angle.
some type of spring-loaded firing pin instead of Repairing failure to cock malfunctions with
a hammer. When the action is manipulated, the bolt-action rifles is as simple as replacing or re-
movement of the bolt (fore and aft) will set the pairing the parts. Typically, if you replace one
firing pin or striker in the cocked position. part of the FCG (like the cocking cam/piece or
Depending on the specific model, the firing the striker or firing pin), you will want to replace
pin/striker will either be cocked when the ac- the corresponding part (like the sear inside the
tion is opened (Mauser K98) or when the action FCG). If the sear surfaces are set at an incorrect
is closed (Mauser K93). With the cock on open angle, you can dress them with stone files and
designs, when the bolt handle is rotated upward sandpaper. Once the parts have been repaired or
(unlocking the action), the striker/firing pin replaced, perform a function check and test fire
cams against a cocking cam/piece, which drives the firearm.

60
 Figure 23a: Cock on open vs. cock on closed designs.

Figure 23b: Cock on open vs. cock on closed designs.

61
Bolt-Action Failure to Fire cause would be a worn or damaged firing pin/
Continuing through the cycle of operations, the striker spring, which would cause light strikes.
next type of malfunction you may experience The next possible cause would be a broken or
would be a failure to fire. There are only two basic damaged firing pin/striker tip or body. The last
reasons why a bolt-action rifle would experience possible cause would be excessive dirt and de-
a failure to fire: broken, damaged, or worn FCG bris inside the FCG. The firing pin/striker and
parts or excessive dirt and debris. The most likely spring are typically housed in a channel in the

Figure 24: Bolt-action sear surfaces.

62
bolt body/head. If there is excessive dirt or debris extractor will not drive the case or will slip over
in the channel, it may slow the firing pin/striker the case rim. If the chamber is excessively dirty
enough to cause a light strike malfunction. or rough, the case will stick to the chamber and
Repairing failure to fire malfunctions is as sim- cause the extractor to jump over the case rim.
ple as cleaning the FCG or replacing the worn If the failure to extract is caused by the extractor
or damaged parts. This means the firing pin/ or its assembly, you can simply replace the dam-
striker and spring. Typically, you will want to aged or worn parts to remedy the issue. If the
replace the firing pin/striker and spring to com- failure to extract is caused by a rough chamber,
pletely “refresh” the FCG. You can replace the the fix is a bit more involved. Repairing a rough
worn or damaged parts, but you will be ensuring chamber can be accomplished on a lathe with
that sometime in the near future you will be re- sandpaper and a dowel, or with Brownells Flex-
placing additional parts. Often, then-new parts Hone line of products.
will put strain against the old parts and cause
them to expire prematurely. Bolt-Action Firearm Ejecting Problems
The last type of malfunction you may experi-
Bolt-Action Unlocking Problems ence with bolt-action firearms would be a fail-
Moving to the next step in the cycle of opera- ure to eject. Ejection with bolt-action rifles is
tions, the next malfunction you may experience (primarily) controlled by the operator. Ejection
would be a failure to unlock. The unlocking step malfunctions can vary with bolt-action firearms
is controlled by the bolt lugs, which means that if because they employ two different ejector types:
there is any damage or burrs on the lugs, the ac- fixed and dynamic. Fixed ejectors are typically
tion may stick and fail to open. Repairing these attached to the receiver of the firearm. As the
malfunctions is as simple as repairing or replac- action cycles and the bolt moves to the rear, the
ing the damaged or broken parts (respectively). extractor will pull the case into the ejector and
cause it to deflect away from the ejector and out
Bolt-Action Failure to Extract Problems of the ejection port. Much of the reliability of
Continuing through the cycle of operations, the this type of ejection is dependent on the shape
next type of malfunction you may experience and location of the ejector and the force of the
would be a failure to extract. When a failure to operator cycling the action.
extract malfunction occurs, either the extrac- Dynamic ejectors are typically spring-driven
tor (or its assembly) has failed or the chamber and live in the bolt face of the bolt/head. As the
is excessively dirty or rough. If the extractor or operator cycles the bolt, the ejector is placing
its assembly is broken, damaged or worn, the constant force against the head cartridge case.

Figure 25: Bolt-action extractors.

63
 Figure 26: Fixed vs. stationary ejectors.

Once the case has been fully extracted from the

chamber, the ejector will immediately try to
throw the case from the ejection port. The reli-
ability of dynamic ejectors is less dependent on
outside forces (the operator) and, in turn, pro-
vides more consistent ejection.
Repairing failure to eject malfunctions with cer-
tain bolt-action firearms is as simple as replacing
broken, damaged, or worn parts. This includes
the extractor/ejector, its assembly and its spring.
If the firearm features an ejector that is fixed to
the receiver and not removable, you may have to
replace the whole receiver or weld up material
to reshape the ejector. Once the assemblies are
replaced, function check and test fire the firearm.

64
 BREAK- AND BOLT-ACTION TROUBLESHOOTING
Malfunction Possible Causes Solution
Failure to Feed With Single-Shot Actions: With Single-Shot Actions:

1. Burrs on the mouth of the 1. Remove burrs and smooth

chamber/no chamfer or bevel. chamber mouth with sandpaper.

2. Dirty chamber. 2. Thoroughly clean the chamber

and lightly oil.
3. Roughly machined chamber.
3. Polish, then clean and oil the
4. Undersized or out-of-spec chamber.
chamber.
4. Recut the chamber to SAAMI
5. Damaged or worn bolt/breech specs.
face.
5. Replace worn or damaged parts.

With Fixed Magazine With Fixed Magazine

Bolt-Actions: Bolt-Actions:

6. Broken, damaged, or worn 6. Replace damaged or worn parts.

magazine parts including the
spring, follower and feed lips. 7. Dress the feed ramp or barrel
Damaged or worn bolt face. mouth and polish the chamber.

7. Rough, damaged or worn feed 8. Replace the extractor or ejector.

ramp or chamber bevel/chamfer.

8. Damaged or broken extractor or

ejector.

With Detachable Magazine With Detachable Magazine

Bolt-Actions: Bolt-Actions:

9. Broken, damaged, or worn 9. Replace the whole magazine

magazine parts including the or parts of the magazine (if
magazine body, feed lips, floor applicable). Reform or reshape
plate, follower and spring. the feed lips.

10.Broken, damaged or worn 10.Replace the magazine catch/

magazine catch/release. release and/or assembly.

65
Malfunction Possible Causes Solution
Failure to Lock With Break-Actions: With Break-Actions:
1. Burrs on the locking surfaces. 1. Remove the burrs and clean up
file marks with sandpaper.
2. Broken, damaged, or heavily
worn locking surfaces. 2. Replace worn or damaged parts
or assemblies.

With Bolt-Actions: With Bolt-Actions:

1. Damage or burrs on the locking 1. Dress the locking lugs and
lugs of the bolt or the locking remove any burrs or damage.
lugs on the receiver. Polish the lugs.

2. Bent or damaged bolt handle. 2. Replace the bolt handle/

assembly or bend the handle (if
applicable).
Loose Lockup 1. Excessive wear on the barrel’s 1. Replace the pivot pin.
(Break-action) locking lugs, pivot pin or pivot
pin recess. 2. Peen the barrel’s locking and
pivot surfaces to tighten up
lockup.
Failure to Cock With Break-Actions: With Break-Actions:
1. Broken, damaged, or worn 1. Replace parts with new or
cocking bar/lever or assembly. slightly used replacements.
Damaged or worn FCG parts.
Damaged hammer strut. 2. Dress sear surfaces with stone
files.
2. Worn sear surface(s).

With Bolt-Actions: With Bolt-Actions:

1. Broken, damaged, or worn 1. Replace broken, damaged, or
striker or assembly. Damaged or worn parts.
worn FCG parts.
2. Dress sear surfaces with stone
2. Worn sear surfaces on the files.
cocking cam/piece or striker.
Failure to Fire 1. Excessive dirt and debris inside 1. Clean the FCG.
the FCG.
2. Replace broken, damaged, or
2. Broken, damaged, or worn FCG worn parts.
parts.

66
Malfunction Possible Causes Solution
Failure to Unlock With Break-Actions: With Break-Actions:
1. Damaged or broken locking 1. Replace damaged or broken
assembly parts. parts.

With Bolt-Actions: With Bolt-Actions:

2. Damage or burrs on the bolt 2. Replace damaged or broken
lugs or lugs on the receiver. parts. Dress the bolt lugs and
polish the surfaces.
Failure to Extract 1. Broken, damaged, or worn 1. Replace broken, damaged, or
extractor or assembly. worn parts or assemblies.

2. Rough chamber. 2. Polish the chamber.

3. Excessively dirty chamber. 3. Thoroughly clean and lightly oil

the chamber.
Failure to Eject With Break-Actions: With Break-Actions:
1. Broken, damaged, or worn 1. Replace broken, damaged, or
ejector or assembly parts. worn parts.

With Bolt-Actions: With Bolt-Actions:

2. Broken, damaged, or worn 2. Replace broken, damaged, or
ejector or assembly parts. worn parts. If the ejector is fixed
to the receiver, you may have to
replace the whole receiver.

67
NOTES
 Chapter 3 - Troubleshooting Lever- and Pump-Actions
TROUBLESHOOTING LEVER- AND PUMP-ACTIONS 71
Lever-Action Firearms 72
PUMP-ACTION FIREARMS 81
Lever- and Pump-Action Troubleshooting 89
70
 Troubleshooting
Lever- and Pump-
Actions
Pump- and lever-actions present unique chal-
lenges because of the increased complexity of
their designs. Both designs typically utilize a tu-
bular magazine that is mounted under the barrel
and feeds rounds backward into the breech from
the front of the receiver. This means there are an
increased number of parts utilized to make these
assemblies function correctly, which means more
things that can go wrong. As long as you have a
basic understanding of how these actions oper-
ate, troubleshooting should be straightforward.

71
LEVER-ACTION FIREARMS and a full magazine, the operator manipulates
the lever (which drives the bolt, elevator/lifter,
The lever-action is a true repeating action de- and cartridge trip/interrupter simultaneously)
sign, which means that every step of the COO to load the first cartridge in the chamber. As the
is performed by the action (even though the ac- operator drives the lever (effort arm) down and
tion is being driven by the operator). Because forward and it pivots around a pin (fulcrum) in
the lever-action design is (somewhat) affected the receiver, the opposite end (load arm) of the
by the skill of the operator, troubleshooting lever drives the bolt backward, unlocking and
lever-actions can sometimes be difficult or frus- opening the breech (Figure 1).
trating. Once you have ruled out ammunition
Simultaneously, assemblies inside the receiver
or operator error, troubleshooting lever-actions
will force the elevator/lifter downward and re-
can be fairly simple.
lease one round from the feeding device onto the
Lever-Action Feeding Problems elevator. The elevator’s downward movement
will trip the cartridge trip/release (which will re-
Beginning with the feeding step in the COO,
lease one cartridge onto the elevator/lifter) and
the first type of malfunction(s) a lever-action
then trip the interrupter/stop (which will stop
firearm can experience would be failures to feed.
the next round in the magazine from entering
Once the lever-action firearm’s magazine tube
the breech). When the operator has reached the
has been loaded by the operator (either through
end of the lever’s stroke, the bolt will be fully to
a loading gate in the receiver or directly into
the rear of its travel, exposing the chamber, while
the tube near its muzzle end), the cartridge is
the elevator/lifter will be angled downward with
fed into the chamber by the action that is being
a single round sitting on its cradle.
driven by the operator. With an empty chamber

Figure 1: Lever-action feeding cycle.

72
 Figure 2: Feeding assembly parts contact wear.

As the operator begins to manipulate the lever Once operator error has been ruled out as the
back and up, the elevator/lifter will begin to rise possible cause of the feed malfunction, you can
and bring the cartridge into alignment with the focus on the remainder of the action. Beginning
bolt. Simultaneously, the bolt will begin to move with the magazine tube, if any part of the feed-
forward as the round begins to rise into its path. ing assembly (including the tube, follower and
The bolt head will meet the cartridge head and spring) were to become broken, damaged, or
begin to drive the cartridge toward the chamber worn, the cartridges would fail to enter the
as the elevator/lifter rises to a point where the breech. If the cartridge stop or interrupter was
cartridge is in perfect alignment with the cham- damaged or broken, cartridges may enter the
ber. The bolt will continue forward, driving and breech prematurely or not at all. If the elevator/
locking the cartridge into the chamber. When lifter is damaged or broken, it may fail to lift and
the lever has completed its stroke, the bolt will align the cartridge in preparation for feeding
be closed and locked on the cartridge and the (Figure 2). If the bolt is broken or damaged, it
elevator/lifter will be in its resting position, hov- may cause misalignment of the cartridge while
ering around the bolt. driving it into the chamber. If the extractor is
There are many things that can go wrong with damaged or broken, it may fail to jump over the
the feeding step of a lever-action firearm. With rim of the cartridge or it may cause misalign-
a fairly complex feeding procedure that involves ment as the round is driven into the chamber.
many separate assemblies, diagnosing feed- Any damage or wear on the lever can also cause
ing malfunctions can sometimes be very tricky. any one of these assemblies to fail.
If any one of these parts or assemblies was to Lever-actions are also susceptible to other com-
become broken, damaged, worn, or excessively mon causes of feeding malfunctions, such as the
dirty, they could easily cause a feeding malfunc- shape of the chamber mouth, a dirty or rough
tion. Typically, the most likely cause of failure to chamber, or excessive dirt and debris in the ac-
feed malfunctions with lever-action firearms is tion. A broken or damaged extractor can also
operator error. There is a very high probability cause feeding malfunctions. Excessive wear on
the operator is short-stroking the action, trying the contact points of any of these parts can
to rapid fire, or working the action inconsistently. cause timing issues in these assemblies that can

73
lead to feeding malfunctions. The lever-action Lever-Action Locking Problems
design is heavily reliant on the timing of each The next type of malfunction you may experi-
assembly for proper function. Timing issues can ence with lever-action firearms would be a fail-
be very difficult to diagnose sometimes because ure to lock. The locking step of a lever-action
the action will behave differently as it is cycled firearm is controlled primarily by the short arm
(by hand) at various speeds. Any “play” that is (load arm) of the lever or by a subassembly that
created in these assemblies from wear or dam- is linked to and activated by the lever. The lever
age can cause intermittent malfunctions that (or subassembly) will act as a locking lug, hold-
may differ in each instance. The round may jam ing the breech closed during discharge.
or hang-up in different areas of the feeding step,
which will make diagnosing the cause of the As the operator drives the lever upward, one of
malfunction a challenge. two things may happen. If the lever is linked
directly to the bolt, the load arm of the lever will
Once the actual cause of the feed malfunction drive the bolt forward, locking the breech with
is determined, repairing feeding malfunctions the leverage of the design. A secondary subas-
with lever-action firearms is as simple as clean- sembly will hold the lever closed to ensure it will
ing, repairing, or replacing the worn or damaged not fire out of battery.
parts or assemblies. This includes the parts and
assemblies of the magazine tube, elevator/lifter, If the action utilizes a subassembly to lock the
cartridge stop and interrupter, bolt and extrac- breech, as the lever is driven closed, it will trip
tor, lever and chamber. If there is a timing issue, the locking assembly, which will arrest the bolt
make certain to replace both parts/assemblies and lock the breech. The bolt may feature a re-
that are involved to avoid further issues later cess designed for a locking lug that is located on
on. Make sure to perform both a function check the lever or in the receiver. As the lever moves
and test fire once you have repaired or replaced upward into the closed position and the bolt
the broken, damaged, or worn assemblies. If the moves forward into the locked position, the
cause of the malfunctions is excessive dirt and locking block/lug will move into the recess/lug
debris, thoroughly clean and lightly lubricate on the bolt and lock the breech (Figure 3).
the action.

Figure 3: Lever-action locking assemblies.

74
If any of the parts or assemblies that control the new bolt. Also, make sure to perform both
locking are excessively dirty, worn, broken, or a function check and test fire once you have re-
damaged, they may cause the breech to fail to paired or replaced the broken, damaged, or worn
lock completely. Starting with the lever, if the assemblies. If the cause of the malfunctions is
lever or locking surface of the load arm of the excessive dirt and debris, thoroughly clean and
lever is worn or damaged or if the lever itself lightly lubricate the action.
is bent, it may fail to drive the bolt completely
closed. If the pivot pin/screw is bent or broken, Lever-Action Cocking Problems
it may also cause the lever to fail to drive the Continuing through the COO, the next type of
bolt completely closed. If the locking recesses malfunction you may encounter would be a fail-
located on the bolt are damaged or worn, this ure to cock. Depending on the specific design of
may also cause the bolt to fail to completely lock. the firearm, the cocking step may be performed
If the firearm utilizes a locking assembly that is by either the action or the operator. When the
separate from the lever and if any part of the as- action controls the cocking step, as the lever is
sembly is broken, damaged, worn, or excessively manipulated down and forward (driving the
dirty, it may fail to lock the bolt closed. The bolt rearward), a ramped section on the rear of
extractor and/or ejector may also cause locking the bolt will drive the hammer back and down
issues. If the extractor (or in some cases with a into the cocked position. When the operator
dynamic ejector) becomes broken or damaged, controls the cocking step, once the lever has
it may fail to allow the bolt to fully seat against been manipulated through its complete stroke
the head of the cartridge and prevent the bolt and there is a cartridge locked in the chamber,
from locking-up against the chamber. Some the operator must drive the hammer by the spur,
lever-action designs may also utilize a small by hand, into the cocked position.
assembly to latch onto the lever in the closed When the hammer is set to the cocked position,
position, providing a small amount of assurance it is trapped in place by the sear or the trigger.
the lever will not automatically fall, unlocking Sear “hooks” on the hammer are trapped by a
the chamber. If this assembly were to become ledge on the sear or trigger itself, which are in
broken, or damaged, it may allow the lever to line with the path of rotation of the hammer’s
prematurely unlock or not lock at all. Failure to hooks. Either the sear or trigger is powered by a
lock can also be a result of an excessively dirty, spring that is constantly driving it into the path
rough, or undersized chamber. A failure to lock of the hammer, preventing unintentional dis-
malfunction can also be the result of operator charge caused by a runaway hammer.
error, caused by short-stroking the action.
Regardless of whether the cocking step is con-
Once the actual cause of the locking malfunc- trolled by the action or by the operator, the
tion is determined, repairing malfunctions with causes for a failure to cock are (typically) the
lever-action firearms is as simple as cleaning, re- same. Typically, the most common cause of a
pairing, or replacing the worn or damaged parts failure to cock would be damaged or broken
or assemblies. This includes the lever, pivot pin/ sear engagement surfaces or broken, damaged,
screw, locking assembly, bolt, or possibly the or dirty FCG parts. If the hooks on the hammer
extractor/ejector. If the bolt must be replaced, or the shearing surfaces on the sear or trigger
make certain to perform a headspace check with are broken, damaged, or worn, the hammer will

75
slip over/past the sear/trigger and fail to cock. If against old parts. In some instances, the sear
the springs that drive the sear/trigger are dam- surfaces can be dressed (outlined earlier in this
aged or worn, they may fail to force the sear/ guide) to try to save hard-to-find parts. Once
trigger into the path of the hammer and cause the parts have been replaced or repaired, thor-
a failure to cock. If either of these assemblies is oughly clean the FCG and lightly lubricate all
excessively dirty, it may slow the parts enough contact points. Perform a function and safety
to cause timing issues in the FCG and cause a check before you perform a final test fire to en-
failure to cock. sure everything functions correctly.
A few least likely causes for a failure to cock Lever-Action Firing Problems
would include the hammer strut and spring,
the bolt, and the safety. If the hammer strut or Moving through the COO, the next type of
spring is damaged or broken, it may not allow malfunction that may occur would be a failure
the hammer to travel far enough back into its to fire. There are only two basic reasons why a
travel to engage the sear/trigger. If the cocking lever-action firearm would experience a failure
surface of the bolt or the face of the hammer is to fire: broken, damaged, or worn FCG parts or
excessively worn or damaged, the bolt may fail excessive dirt and debris. The most likely cause
to drive the hammer down far enough to engage would be a worn or damaged firing pin, ham-
the sear/trigger. Depending on the design of the mer, or hammer spring. If the hammer or firing
FCG, the safety may block the movement of the pin is damaged or broken, the firing pin may
hammer/sear/trigger. If the safety were to fail, fail to even reach the primer. If the hammer/
it could inadvertently block the hammer/sear/ mainspring is damaged or worn, the firing pin
trigger and prevent the hammer from cocking. may only create a “light strike.”

Repairing failure to cock malfunctions is as sim- The next possible cause would be excessive dirt
ple as replacing broken, damaged, or worn FCG and debris inside the FCG. The firing pin spring
parts. This includes the hammer, strut, ham- is housed in a channel in the bolt head. If there
mer spring, sear/trigger, bolt, safety, and springs. is excessive dirt or debris in the channel, it may
You may want to replace both sear surfaces (the slow the firing pin enough to cause a light strike
sear/trigger and hammer) to ensure there are no malfunction or seize the firing pin completely.
further complications from new parts working

Figure 4: Parts of a lever-action FCG that could cause a failure to cock.

76
 Figure 5: Lever-action FCG parts.

Another and less likely cause of a failure to fire Some designs also utilize a separate locking as-
would come from a malfunctioning safety. If the sembly that is activated by the lever.
safety were to fail, it could jam the FCG and If any of the parts or assemblies that control
prevent either the trigger or hammer from mov- unlocking are excessively dirty, worn, broken, or
ing. The safety could also apply enough drag to damaged, they may cause the breech to fail to
FCG parts to cause a light strike. open. Starting with the lever, if the lever or lock-
Repairing failure to fire malfunctions is as simple ing surface of the load arm of the lever is worn
as cleaning the FCG or replacing the worn or or damaged or if the lever itself is bent, it may
damaged parts. This means the firing pin, ham- fail to drive the bolt open. If the pivot pin/screw
mer, hammer spring, strut, sear/trigger or safety. is bent or broken, it may also cause the lever
Typically, you will want to replace the worn or to fail to drive the bolt completely open. If the
damaged parts and springs to completely “refresh” locking recesses located on the bolt are dam-
the FCG. You can replace the worn or damaged aged or worn, this may also cause the bolt to fail
parts, but this will ensure that sometime in the to completely unlock. If the firearm utilizes a
near future you will be replacing additional parts. locking assembly that is separate from the lever,
Often, new parts will put strain against the old if any part of the assembly is broken, damaged,
parts and cause them to expire prematurely. worn, or excessively dirty, it may fail to release
the bolt and unlock the breech. The safety can
Lever-Action Unlocking Problems also create a failure to unlock with some designs,
The next type of malfunction that you may ex- as it can block the hammer/trigger and prevent
perience would be a failure to unlock. Like the the bolt from moving rearward; but this is the
locking step, the unlocking step is controlled least likely scenario.
primarily by the operator. When the operator Once the actual cause of the unlocking mal-
manipulates the lever down and forward, the function is determined, repairing malfunctions
short arm (load arm) of the lever or linkage will with lever-action firearms is as simple as clean-
drive the bolt rearward, unlocking the breech. ing, repairing, or replacing the worn or damaged

77
parts or assemblies. This includes the lever, damaged, or worn, it will jump over the case
pivot pin/screw, locking assembly, or possibly rim and leave the empty case in the chamber.
the bolt or safety. If the bolt must be replaced, If the extractor spring or the extractor itself be-
make certain to perform a headspace check with comes weak or worn, the empty case may only
the new bolt. Also, make sure to perform both be partially extracted before the extractor claw
a function check and test fire once you have re- slips over the case rim. If the extractor pin (if
paired or replaced the broken, damaged, or worn applicable) is bent or broken, it may also cause
assemblies. If the cause of the malfunctions is a fail to extract.
excessive dirt and debris, thoroughly clean and A failure to extract malfunction can also be
lightly lubricate the action. caused by the chamber of the firearm. If the
Lever-Action Extracting Problems chamber is excessively rough, it may place too
much friction against the case and cause extrac-
Continuing through the COO, the next type of tion malfunctions. If the chamber is excessively
malfunction that may occur would be a failure dirty, it may also cause a failure to extract.
to extract. When the operator manipulates the
lever to unlock the action, the extractor (affixed If the failure to extract is caused by the extractor
to the bolt) will begin to pull the empty case or its assembly, you can simply replace the dam-
from the chamber as the bolt is driven rear- aged or worn parts to remedy the issue. If the
ward by the lever. The extractor will hold the failure to extract is caused by a rough chamber,
empty case against the bolt face until the round the fix is a bit more involved. Repairing a rough
is ejected. The extractor may feature an integral chamber can be accomplished on a lathe with
spring design or may use a separate spring to sandpaper and a dowel, or with Brownells Flex-
drive the extractor claw. Hone line of products.

If any part of the extractor assembly were to fail Lever-Action Ejecting Problems
because of breakage, damage, or wear, it would The last type of malfunction that may occur
cause a failure to extract. This includes the ex- would be a failure to eject. Lever-action firearms
tractor itself and the extractor spring and pin typically feature a fixed ejector that is integral
(if applicable). If the extractor claw is broken, to or affixed to the receiver. When the operator

Figure 6: Lever-action extractor.

78
 Figure 7: Lever-action ejector.

manipulates the lever and drives the bolt rear- firearm may start to experience failure to ejects.
ward, the extractor will pull the empty case from If the firearm utilizes a fixed (or sprung) ejec-
the chamber and directly into the ejector, which tor located in the receiver and it becomes worn
will kick the case from the breech. Sometimes, or damaged, you will begin to experience erratic
the ejector design utilizes a small flat (or coil) ejection or ejection that fails to clear the breech.
spring to constantly place force against the ejec- If the design utilizes a spring and it becomes
tor, but will allow it to slightly compress as the worn or damaged, the empty cases may fail to
bolt passes over it. This design allows for the eject at all. If the design utilizes an ejector lo-
largest possible ejection surface without affect- cated in the bolt face and the ejector or springs
ing function. You may also encounter dynamic become worn or damaged, the firearm will
ejectors located in the face of the bolt that place experience erratic ejection or may fail to eject
constant force on the case head. empty cases at all.
If the firearm utilizes a fixed or sprung ejector Repairing failure to eject malfunctions with
affixed to the receiver, much of the force and certain lever-action firearms is as simple as re-
reliability of ejection is going to come from skill placing broken, damaged, or worn parts. This
of the operator. This means that the operator includes the ejector and, if applicable, its spring.
must manipulate the lever fast enough to drive If the firearm features an ejector that is fixed to
the bolt and empty case into the ejector so that the receiver and is not removable, you may have
the case will clear the breech. If the design uti- to replace the whole receiver or weld up material
lizes a dynamic ejector that lives in the bolt face, to reshape the ejector. If the ejector is located
ejection is less reliant on the operator. in the bolt face, you simply need to replace the
If the ejector or ejector assembly were to become parts. Once the assemblies are replaced, func-
broken, damaged, worn, or excessively dirty, the tion check and test fire the firearm.

79
THIS PAGE INTENTIONALLY BLANK

80
 fed into the chamber by the action that is being

Pump-Action driven by the operator. With an empty chamber

and a full magazine, the operator manipulates
Firearms the forend, or slide (which drives the bolt/car-
rier, elevator/lifter and cartridge trip/interrupter
Like the lever-action, the pump-action is a true simultaneously), to load the first cartridge in the
repeating action design, which means that ev- chamber. As the operator drives the slide back-
ery step of the COO is performed by the action ward, the slide/action bar (which is fixed to the
(even though the action is being driven by the slide) drives the bolt/carrier backward, unlock-
operator). Because the pump-action design is ing and opening the breech.
(somewhat) affected by the skill of the operator,
Simultaneously, assemblies on the bolt or inside
troubleshooting pump-actions can sometimes
the receiver will force the elevator/lifter down-
be difficult or frustrating. Once you have ruled
ward and release one round from the feeding
out ammunition or operator error, troubleshoot-
device onto the elevator. Depending on design,
ing pump-actions can be fairly simple.
the elevator’s downward movement, the bolt
Pump-Action Feeding Problems moving rearward, or the slide/action bar(s) will
trip the cartridge trip/release (which will release
Beginning with the feeding step in the COO, one cartridge onto the elevator/lifter) and then
the first type of malfunction(s) a pump-action trip the interrupter/stop (which will stop the
firearm can experience would be failures to feed. next round in the magazine from entering the
Once the pump-action firearm’s magazine tube breech). When the operator has reached the end
has been loaded by the operator, the cartridge is

Figure 8: Pump-action feeding cycle.

81
of the slide’s stroke, the bolt will be fully to the breech prematurely or not at all. If the elevator/
rear of its travel (exposing the chamber), while lifter is damaged or broken, it may fail to lift and
the elevator/lifter will be angled downward with align the cartridge in preparation for feeding. If
a single round sitting on its cradle. the bolt or bolt carrier is broken or damaged, it
As the operator begins to manipulate the slide may cause misalignment of the cartridge while
forward, the elevator/lifter will begin to rise and driving it into the chamber. If the extractor(s) is
bring the cartridge into alignment with the bolt. damaged or broken, it may fail to jump over the
Simultaneously, the bolt will begin to move for- rim of the cartridge or it may cause misalign-
ward as the round begins to rise into its path. ment as the round is driven into the chamber.
The bolt head will meet the cartridge head and Any damage or wear on the slide or action/slide
begin to drive the cartridge toward the chamber bars can also cause any one of these assemblies
as the elevator/lifter rises to a point where the to fail. Pump-actions are also susceptible to oth-
cartridge is in perfect alignment with the cham- er common causes of feeding malfunctions, such
ber. The bolt will continue forward, driving and as excessive dirt and debris in the action and a
locking the cartridge into the chamber. When dirty or rough chamber.
the slide has completed its stroke, the bolt will Excessive wear on the contact points of any of
be closed and locked on the cartridge and the these parts can cause timing issues in these as-
elevator/lifter will be in its resting position, hov- semblies that can lead to feeding malfunctions.
ering around the bolt. The pump-action design is heavily reliant on
There are many things that can go wrong with the timing of each assembly for proper function.
the feeding step of a pump-action firearm. With Timing issues can be very difficult to diagnose
a fairly complex feeding procedure that involves sometimes because the action will behave differ-
many separate assemblies, diagnosing feed- ently as it is cycled (by hand) at various speeds.
ing malfunctions can sometimes be very tricky. Any “play” that is created in these assemblies
If any one of these parts or assemblies was to from wear or damage can cause intermittent
become broken, damaged, worn, or excessively malfunctions that may differ in each instance.
dirty, they could easily cause a feeding malfunc- The round may jam or hang-up in different ar-
tion. Typically, the most likely cause of failure to eas of the feeding step, which will make diag-
feed malfunctions with pump-action firearms is nosing the cause of the malfunction a challenge.
operator error. There is a very high probability Once the actual cause of the feed malfunction
the operator is short-stroking the action when is determined, repairing feeding malfunctions
trying to rapid fire. with pump-action firearms is as simple as clean-
Once operator error has been ruled out as the ing, repairing, or replacing the worn or damaged
possible cause of the feed malfunction, you can parts or assemblies. This includes the parts and
focus on the remainder of the action. Beginning assemblies of the magazine tube, elevator/lifter,
with the magazine tube, if any part of the feed- cartridge stop and interrupter, bolt, carrier and
ing assembly (including the tube, follower and extractor, slide, action/slide bars and chamber.
spring) were to become broken, damaged, or If there is a timing issue, make certain to re-
worn, the cartridges would fail to enter the place both parts/assemblies that are involved
breech. If the cartridge stop or interrupter was to avoid further issues later on. Also, make sure
damaged or broken, cartridges may enter the to perform both a function check and test fire

82
once you have repaired or replaced the broken, If the design does not utilize a bolt carrier
damaged, or worn assemblies. If the cause of the (Winchester 1897), then when the bolt bottoms
malfunctions is excessive dirt and debris, thor- out against the barrel, a subassembly or the el-
oughly clean and lightly lubricate the action. evator/lifter will rise upward, engaging the bolt
and locking the breech. The locking assembly is
Pump-Action Locking Problems either tripped by the bolt or by the slide/action
The next type of malfunction you may experience bar(s). With the Winchester 1897, the elevator/
with pump-action firearms would be a failure lifter doubles as a locking assembly.
to lock. With pump-action firearms, the lock- Regardless of design, once the breech is locked,
ing step in the COO is typically accomplished a secondary assembly will provide a secondary,
with some type of locking assembly. When the redundant lock that also doubles as a means
operator manipulates the slide forward to lock to unload the firearm. The bolt/action release
the breech, the slide/action bar(s) will drive the blocks the bolt/carrier and prevents the action
bolt/carrier forward until the bolt bottoms out from being cycled once the action is loaded. A
against the chamber end of the barrel. small arm or tab will engage a recess in the bolt/
Depending on design, the breech may lock in carrier or block the rear of the bolt and prevent
one of two ways. If the design utilizes a bolt car- its rearward movement until the round is fired or
rier (Mossberg 500/Remington 870), then when the operator manipulates the bolt/action release.
the bolt bottoms out against the barrel, the car- If any of the parts that control locking are bro-
rier will continue forward, driving a locking lug ken, damaged, worn, or excessively dirty, they
upward into a locking recess. A protrusion on can cause a failure to lock. If the slide/action
the bolt carrier will cam against a locking lug bar is broken or damaged, it may fail to drive
(that pivots in the body of the bolt) and drive the bolt completely forward or may fail to trip
the locking lug upward. Depending on specific the locking assembly. With carrier designs, if
design, the locking lug in the bolt will engage a the carrier, locking lug, or barrel/receiver is bro-
cutout or recess that is either located in the bar- ken, damaged, or worn, the breech may fail to
rel (which is recessed into the receiver) or into a lock completely or may come unlocked during
locking recess directly in the receiver.

Figure 9: Parts of a pump-action locking assembly.

83
 Figure 10: Parts of a pump-action FCG that could cause a failure to cock.

discharge. With non-carrier designs, if the slide/ carrier will drive the hammer back and down
action bar(s) or bolt or elevator/locking assem- into the cocked position. When the operator
bly is broken, damaged or worn, it can also lead controls the cocking step, once the slide has
to a failure to lock. If any part of the bolt/action been manipulated through its complete stroke
release assembly is broken, damaged, or worn, and there is a cartridge locked in the chamber,
it may allow the breech to unlock during dis- the operator must drive the hammer by the spur,
charge and create a very dangerous situation. If by hand, into the cocked position.
any of these parts become excessively dirty, it When the hammer is set to the cocked position,
may also lead to locking malfunctions. it is trapped in place by the sear or the trigger.
Once the actual cause of the locking malfunc- Sear “hooks” on the hammer are trapped by a
tion is determined, repairing malfunctions with ledge on the sear or trigger itself, which are in
pump-action firearms is as simple as cleaning, line with the path of rotation of the hammer’s
repairing, or replacing the worn or damaged hooks. Either the sear or trigger is powered by a
parts or assemblies. This includes the slide, spring that is constantly driving it into the path
slide/action bar(s), locking lug or locking as- of the hammer, preventing unintentional dis-
sembly, bolt/carrier or possibly the barrel/re- charge caused by a runaway hammer.
ceiver or even the elevator/lifter. If the bolt must Regardless of whether the cocking step is con-
be replaced, make certain to perform a head- trolled by the action or by the operator, the
space check with the new bolt. Also, make sure causes for a failure to cock are (typically) the
to perform both a function check and test fire same. Typically, the most common cause of a
once you have repaired or replaced the broken, failure to lock would be damaged or broken sear
damaged, or worn assemblies. If the cause of the engagement surfaces or broken, damaged, or
malfunctions is excessive dirt and debris, thor- dirty FCG parts. If the hooks on the hammer
oughly clean and lightly lubricate the action. or the shearing surfaces on the sear or trigger
Pump-Action Cocking Problems are broken, damaged, or worn, the hammer will
slip over/past the sear/trigger and fail to cock. If
Continuing through the COO, the next type of the springs that drive the sear/trigger are dam-
malfunction you may encounter would be a fail- aged or worn, they may fail to force the sear/
ure to cock. Depending on the specific design of trigger into the path of the hammer and cause
the firearm, the cocking step may be performed a failure to cock. If either of these assemblies is
by either the action or the operator. When the excessively dirty, it may slow the parts enough
action controls the cocking step, as the slide is to cause timing issues in the FCG and cause a
manipulated backward (driving the bolt rear- failure to cock.
ward), a ramped section on the rear of the bolt/

84
A few least likely causes for a failure to cock contact points. Perform a function and safety
would include the hammer strut and spring, the check before you perform a final test fire to en-
bolt, and the safety. If the hammer strut or spring sure everything functions correctly.
is damaged or broken, it may not allow the ham-
mer to travel far enough back into its travel to Pump-Action Firing Problems
engage the sear/trigger. If the cocking surface Moving through the COO, the next type of
of the bolt/carrier or the face of the hammer is malfunction that may occur would be a failure
excessively worn or damaged, the bolt may fail to fire. There are only two basic reasons why a
to drive the hammer down far enough to engage pump-action firearm would experience a failure
the sear/trigger. Depending on the design of the to fire: broken, damaged, or worn FCG parts or
FCG, the safety may block the movement of the excessive dirt and debris. The most likely cause
hammer/sear/trigger. If the safety were to fail, would be a worn or damaged firing pin, ham-
it could inadvertently block the hammer/sear/ mer, or hammer spring. If the hammer or firing
trigger and prevent the hammer from cocking. pin is damaged or broken, the firing pin may
Repairing failure to cock malfunctions is as sim- fail to even reach the primer. If the hammer/
ple as replacing broken, damaged, or worn FCG mainspring is damaged or worn, the firing pin
parts. This includes the hammer, strut, ham- may only create a “light strike.”
mer spring, sear/trigger, bolt, safety, and springs. The next possible cause would be excessive
You may want to replace both sear surfaces (the dirt and debris inside the FCG. The firing pin
sear/trigger and hammer) to ensure there are no spring is housed in a channel in the bolt head. If
further complications from new parts working there is excessive dirt or debris in the channel, it
against old parts. In some instances, the sear may slow the firing pin enough to cause a light
surfaces can be dressed (outlined earlier in this strike malfunction or seize the firing pin com-
guide) to try to save hard-to-find parts. Once pletely. Because the locking lug lives in the bolt
the parts have been replaced or repaired, thor- and the firing pin passes through the lug, if the
oughly clean the FCG and lightly lubricate all

Figure 11: Pump-action FCG parts.

85
locking lug is broken, bent, or damaged, it may If any of the parts or assemblies that control
slow or stall the firing pin and cause a failure to unlocking are excessively dirty, worn, broken, or
fire or light strike. damaged, they may cause the breech to fail to
Another and less likely cause of a failure to fire open. Starting with the slide, if the slide or slide
would come from a malfunctioning safety. If the bar(s) is worn or damaged or if the slide bar(s)
safety were to fail, it could jam the FCG and itself is bent, it may fail to drive the bolt open.
prevent either the trigger or hammer from mov- If the bolt/carrier or locking lug(s), including
ing. The safety could also apply enough drag to the lug recesses in the barrel/receiver, is broken,
FCG parts to cause a light strike. damaged, or worn, the action may become stuck
and fail to unlock. If the locking assembly or
Repairing failure to fire malfunctions is as elevator/lifter is broken or damaged, it may fail
simple as cleaning the FCG or replacing the to release the bolt and unlock the breech. If the
worn or damaged parts. This means the firing bolt/action release assembly is broken, damaged,
pin, hammer, hammer spring, strut, sear/trigger, or worn, it may fail to clear the path of the bolt/
locking lug or safety. Typically, you will want to carrier and not allow the breech to open. The
replace the worn or damaged parts and springs safety can also create a failure to unlock with
to completely “refresh” the FCG. You can re- some designs, as it can block the hammer/trig-
place the worn or damaged parts, but doing so ger and prevent the bolt from moving rearward;
will ensure that sometime in the near future you but this is the least likely scenario.
will be replacing additional parts. Often, new
parts will put strain against the old parts and Once the actual cause of the unlocking mal-
cause them to expire prematurely. function is determined, repairing malfunctions
with pump-action firearms is as simple as clean-
Pump-Action Unlocking Problems ing, repairing, or replacing the worn or damaged
The next type of malfunction that you may ex- parts or assemblies. This includes the slide,
perience would be a failure to unlock. Like the slide/action bars, locking assembly, locking
locking step, the unlocking step is controlled lug, elevator/lifter, bolt/action release, or pos-
primarily by the operator. When the operator sibly the bolt/carrier or safety. If the bolt must
manipulates the slide backward, the slide/action
bar(s) will drive the bolt rearward, unlocking the
breech. When the slide/action bar(s) begins to
drive the bolt carrier rearward, the lug on the
carrier will clear the path of the locking lug and
allow the lug to drop out of the locking recess in
the barrel/receiver.
Some designs also utilize a separate locking
assembly that is activated by the slide/action
bar(s) or bolt. Some designs utilize an elevator/
lifter that doubles as a locking surface. When
the slide/action bar begins to drive the bolt rear-
ward, a trip on the bolt or slide/action bar(s) will
begin to force the elevator/lifter down and out
of the path of the bolt so the breech can unlock. Figure 12: Pump-action extractor.

86
be replaced, make certain to perform a head- If the extractor spring or the extractor itself be-
space check with the new bolt. Also, make sure comes weak or worn, the empty case may only
to perform both a function check and test fire be partially extracted before the extractor claw
once you have repaired or replaced the broken, slips over the case rim. If the extractor pin (if
damaged, or worn assemblies. If the cause of the applicable) is bent or broken, it may also cause
malfunctions is excessive dirt and debris, thor- a fail to extract.
oughly clean and lightly lubricate the action. A failure to extract malfunction can also be
Pump-Action Extracting Problems caused by the chamber of the firearm. If the
chamber is excessively rough, it may place too
Continuing through the COO, the next type of much friction against the case and cause extrac-
malfunction that may occur would be a failure tion malfunctions. If the chamber is excessively
to extract. When the operator manipulates the dirty, it may also cause a failure to extract. If the
slide to unlock the action, the extractor (affixed failure to extract is caused by the extractor or its
to the bolt) will begin to pull the empty case assembly, you can simply replace the damaged
from the chamber as the bolt is driven rearward or worn parts to remedy the issue. If the failure
by the slide/action bar(s). The extractor will to extract is caused by a rough chamber, the fix is
hold the empty case against the bolt face until a bit more involved. Repairing a rough chamber
the round is ejected. The extractor may feature can be accomplished on a lathe with sandpaper
an integral spring design or may use a separate and a dowel, or with Brownells Flex-Hone line
spring to drive the extractor claw. of products.
If any part of the extractor assembly were to fail
because of breakage, damage, or wear, it would Pump-Action Ejecting Problems
cause a failure to extract. This includes the ex- The last type of malfunction that may occur
tractor itself and the extractor spring and pin would be a failure to eject. Pump-action fire-
(if applicable). If the extractor claw is broken, arms typically feature a fixed ejector that is inte-
damaged, or worn, it will jump over the case gral to or affixed to the receiver. When the op-
rim and leave the empty case in the chamber. erator manipulates the slide and drives the bolt

Figure 13: Pump-action ejector.

87
rearward, the extractor will pull the empty case If the ejector or ejector assembly were to become
from the chamber and directly into the ejec- broken, damaged, worn, or excessively dirty, the
tor, which will kick the case from the breech. firearm may start to experience failure to ejects.
Sometimes, the ejector design utilizes a small If the ejector is worn or damaged, the firearm
flat (or coil) spring to constantly place force will experience erratic ejection. If the ejector
against the ejector, but will allow it to slightly is broken, the empty cases may fail to eject the
compress as the bolt passes over it. This design breech and become jammed in the action.
allows for the largest possible ejection surface Repairing failure to eject malfunctions with
without affecting function. With the pump- pump-action firearms is as simple as replacing
action design, much of the force and reliability broken, damaged, or worn parts. This includes
of ejection is going to come from skill of the op- the ejector and, if applicable, its spring. If the
erator. This means that the operator must ma- firearm features an ejector that is fixed to the
nipulate the slide fast enough to drive the bolt receiver and not removable, you may have to re-
and empty case into the ejector so that the case place the whole receiver or weld up material to
will clear the breech. reshape the ejector. Once the assemblies are re-
placed, function check and test fire the firearm.

88
 LEVER- AND PUMP-ACTION TROUBLESHOOTING
Malfunction Possible Causes Solution

Failure to Feed 1. Burrs on the mouth of the 1. Remove burrs and smooth
chamber/no chamfer or bevel. chamber mouth with sandpaper.
2. Dirty chamber. 2. Thoroughly clean the chamber
3. Roughly machined chamber. and lightly oil.

4. Undersized or out-of-spec 3. Polish, then clean and oil the

chamber. chamber.

5. Damaged or worn bolt/breech 4. Recut the chamber to SAAMI

face. specs.

Broken, damaged, or worn 5. Replace worn or damaged

magazine parts including the parts.
spring, tube, follower and stop/
interrupter.
Damaged or worn elevator/lifter,
lever/slide or bolt face/carrier.
Damaged or broken extractor.

Failure to Lock With Lever-Actions: With Lever-Actions:

1. Broken, damaged or worn lever, 1. 1 – 4: Replace worn or dam-
pivot pin/screw, or bolt. aged parts.
2. Broken, damaged or worn lock- 5. Polish, then clean and oil the
ing assembly parts. chamber. Recut the chamber
3. Broken or damaged extractor to SAAMI specs.
or ejector.
4. Broken or damaged lever latch.
5. Excessively dirty, rough or un-
dersized chamber.

With Pump-Actions: With Pump-Actions:

1. Broken, damaged, or worn 1. 1 – 4: Replace worn or dam-
slide, slide/action bar(s), or bolt aged parts.
carrier. 5. Thoroughly clean and oil the
2. Broken, damaged, or worn bolt, chamber.
locking assembly/locking lug or
elevator/lifter.
3. Broken, damaged, or worn bar-
rel or receiver.
4. Broken, damaged, or worn bolt/
action release.
5. Excessive dirt and debris in the
locking assemblies.

89
Malfunction Possible Causes Solution

Failure to Cock 1. Broken, damaged, or worn sear 1. Replace worn or damaged

surfaces. Broken or damaged parts. Some sear surfaces can
FCG parts, including the strut, be dressed and polished.
springs and selector. 2. Replace worn or damaged
2. Worn cocking surfaces on the parts.
bolt/carrier/hammer.

Failure to Fire 1. Excessive dirt and debris inside 1. Clean the FCG.
the FCG. 2. Replace broken, damaged, or
2. Broken, damaged or worn FCG worn parts.
parts.

Failure to Unlock With Lever-Actions: With Lever-Actions:

1. Broken, damaged, or worn lock- 1. Broken, damaged, or worn
ing assemblies, including the parts.
lever, lever pin, locking assem-
bly, bolt and safety.

With Pump-Actions: With Pump-Actions:

1. Broken, damaged, or worn lock- 1. Replace broken, damaged, or
ing assemblies, including the worn parts.
slide, slide/action bar(s), bolt/
carrier, elevator/lifter, locking
lug, or bolt/action release.

Failure to Extract 1. Broken, damaged, or worn 1. Replace broken, damaged, or

extractor or assembly. worn parts or assemblies.
2. Rough chamber. 2. Polish the chamber.
3. Excessively dirty chamber. 3. Thoroughly clean and lightly oil
the chamber.

Failure to Eject 1. Broken, damaged, or worn ejec- 1. Replace broken, damaged, or

tor or assembly parts. worn parts.

90
 Chapter 4 - Troubleshooting Revolvers
TROUBLESHOOTING REVOLVERS 93
Single-Action Revolvers 93
Double-Action Revolvers 101
Cylinder Gap 107
Revolver Action Troubleshooting 109
92
 Troubleshooting
Revolvers
Revolvers present many challenges if you are not
completely familiar with their design. Revolver
actions differ from every other action type and
have a unique cycle of operations. There are two
basic revolver action designs: single and double
action. The main difference between the two
action types lies in the function of the fire con-
trol group.

SINGLE-ACTION REVOLVERS
The single-action system is the original re-
volver action and the oldest repeating handgun
design. The single-action design is also much
simpler compared to the double-action design
and slightly easier to diagnose. Much of the

93
 Figure 1: The first stage of the feeding step of a single-action revolver.

single-action revolver’s cycle of operations is the operator closes the loading gate to prevent
controlled by the operator, which makes opera- rounds from falling out of the cylinder. This is
tor error a factor when diagnosing issues. Once the end of the first stage of the loading process.
operator error has been ruled out, you can focus Once the cylinder has been loaded and the load-
on the remainder of the factors. ing gate has been closed, the second stage of the
Single-Action Revolver Feeding Problems feeding process begins. This second stage of the
process is semi-automated and is activated when
Beginning with the feeding step in the COO, the operator sets the hammer from half-cock to
the first type of malfunction(s) a single-action full-cock. As the operator moves the hammer
revolver action can experience would be failures back and down into the cocked position, link-
to feed. The feeding step of a single-action re- age on the hammer will activate the hand as-
volver is a two-phase process that involves both sembly, driving it up and forward under spring
the action and the operator. The first stage of the force, which will act upon the ratchet, causing
feeding step of a single-action revolver involves the cylinder to rotate clockwise around the base
setting the hammer to the “half-cock” position, pin and bring the first chamber into alignment
which (through linkage) moves the hand out of with the barrel. Simultaneously, the cocking of
the path of the ratchet and clears the cylinder the hammer will also force the trigger to drive
stop from the cylinder stop notch*. This frees the cylinder stop upward, locking the cylinder
the movement of the cylinder around the base into alignment with the barrel. This is the end
pin. A hinged part known as the loading gate of the second stage of the feeding process.
is swung outward from the frame, exposing the
first chamber of the cylinder. The operator loads Because the feeding step of a single-action re-
a single cartridge into the exposed chamber and volver involves two separate stages, you must
rotates the cylinder clockwise (looking from the diagnose each stage separately. Beginning with
breech end) to expose the next chamber. The op- the first stage, if the leading edge of the cham-
erator will continue to load each chamber until ber is burred or does not feature a chamfer, it
the cylinder is full. Once the cylinder is loaded, may cause the cartridge to catch the edge of the
chamber. If the hammer or hand assembly is

*Disclaimer: Some manufacturers use different terms for the same parts of a revolver:
1. The term “finger” is also used in describing hand.
2. Cylinder stop is also known as the cylinder “bolt,” “latch,” or “lock.”
3. Cylinder stop notch is also referred to as the “cylinder bolt stop.”

94
 Figure 2: The second stage of the feeding step of a single-action revolver.

broken, damaged, or worn, it may fail to release Once you have diagnosed the feeding problem,
the ratchet when the hammer is set to half-cock. repairing feeding issues with a single-action
If there is excessive dirt, debris, or moisture be- revolver is as simple as replacing the broken,
tween the cylinder and base pin, it may cause the damaged, or worn parts and assemblies. If the
cylinder to seize. A roughly machined or under- firearm is excessively dirty, you will need to
sized chamber can also lead to feeding issues. clean the parts/assemblies that are causing the
During the second stage of a single-action re- malfunctions. This includes the cylinder, cham-
volver’s feeding step, if the hammer, hand assem- bers and base pin, as well as the ratchet. Other
bly (including spring), or ratchet is damaged or parts that may need replacement would include
broken, it will prevent the cylinder from rotating the hammer/trigger and hand. Once the parts
and aligning the next chamber with the barrel. If have been replaced, you will need to perform a
either the hand or ratchet is excessively worn, it function and safety check of the firearm to ver-
will cause a timing issue. Either situation can be ify there is no timing issue. If the chambers do
extremely dangerous. There is a possibility that not feature a bevel/chamfer along their leading
the hammer can strike the primer of a cartridge edge, you will need to form one. Once the fire-
that is slightly misaligned with the barrel. arm has been function and safety checked, you
will need to test fire it.
If you suspect the hand or ratchet is broken,
damaged, or worn, you can verify by watching Single-Action Revolver Locking Problems
and checking the cylinder. With an empty fire- The next type of malfunction you may experi-
arm, slowly set the hammer to the cocked po- ence with revolver actions would be a failure
sition. Watch the cylinder as it rotates around to lock. The locking step of a single-action re-
the base pin and carefully listen for a “click” as volver is accomplished when the hammer is set
the cylinder stop engages the cylinder before to the cocked position. As the hammer travels
the hammer is fully cocked. Once the hammer rearward, driving the hand into the ratchet and
is fully cocked, check the cylinder to verify it is causing the cylinder to rotate around the base
locked in place. If the cylinder rotates slightly pin, the hammer will also drive the trigger so
and you hear and feel the cylinder stop, you have
a timing issue.

95
that the sear surface of the trigger engages the cylinder stop, ratchet or cylinder. If the hammer,
hammer’s hooks. As the trigger moves into po- trigger, or hand is broken, damaged, or worn, it
sition to trap the hammer, it will drive the cyl- may fail to drive the cylinder or cylinder stop
inder stop upward (through linkage and spring or fail to drive the parts throughout their full
force) so that it can engage the stop notch in travel. If the cylinder stop notch or the cylinder
the cylinder. stop is damaged or worn, it may cause play in
While the cylinder is rotating around the base the cylinder or may allow the cylinder to un-
pin, it brings the next chamber into alignment lock. If the spring that drives the cylinder stop is
with the cylinder stop, and moves upward en- worn or damaged, it may also allow the cylinder
gaging a ramped section (lead) just ahead of the to unlock.
stop notch. The stop will ride the lead into the Repairing locking malfunctions with single-ac-
stop notch and arrest the cylinder’s movement, tion revolvers is as simple as replacing the bro-
aligning the chamber with the barrel. The stop ken, damaged, or worn parts. This includes the
should engage the notch and lock the cylinder hammer, trigger, hand, cylinder stop or the cyl-
slightly before the hammer is fully cocked. inder itself. Once the damaged parts have been
If any part of the locking assembly or parts replaced, you will need to perform a function
that drive the locking assembly become broken, and safety check, as well as check the timing. If
damaged, or worn, the firearm may fail to lock. you must replace the cylinder, you will also have
This includes the hammer, trigger, hand, spring, to perform a headspace check.

Figure 3: Parts of a single-action revolver locking assembly.

96
Single-Action Revolver Cocking Problems Repairing failure to cock malfunctions is as
Continuing through the COO, the next type simple as replacing broken, damaged, or worn
of malfunction you may encounter would be a FCG parts. This includes the hammer, strut,
failure to cock. Because of the simplicity of the hammer spring, trigger, and trigger springs. You
single-action revolver, there are only a few parts may want to replace both sear surfaces (the trig-
that can cause a failure to cock. When the op- ger and hammer) to ensure there are no further
erator drives the hammer backward and down complications from new parts working against
(against the pressure of the mainspring) into the old parts. In some instances, the sear surfaces
cocked position, the trigger spring will drive the can be dressed (outlined earlier in this guide)
trigger’s sear surface, which is typically located to try to save hard-to-find parts. Once the parts
on a tang on the rear of the trigger, into the path have been replaced or repaired, thoroughly clean
of the hammer’s sear hooks, arresting the ham- the FCG and lightly lubricate all contact points.
mer’s movement. Perform a function and safety check before you
perform a final test fire to ensure everything
If any part of the FCG is broken, damaged, or functions correctly.
worn, the revolver may fail to cock. If the sear
surfaces on the trigger or hammer are broken or Single-Action Revolver Firing Problems
damaged, the hammer may fail to cock. If the Moving through the COO, the next type of
sear surfaces are excessively worn, the hammer malfunction that may occur would be a failure
may cock temporarily and fall unintentionally to fire. Depending on specific design, the firing
if bumped or tapped. If the trigger spring is step of a single-action revolver may vary slightly.
damaged or worn, it may fail to drive the trig- The biggest difference between design types is
ger’s sear surface into the path of the hammer’s the number of parts. Older guns tend to use less
hooks. If the hammer strut is broken or dam- parts, while newer guns utilize more parts for
aged, it may not allow the hammer to move far safety and legal concerns.
enough back to reach the cocked position.

Figure 4: Sear surfaces of a single-action revolver. Figure 5: Hammer with integral firing pin.

97
 Later single-action revolver designs will utilize
a multi-piece hammer/firing pin assembly. The
hammer features a flat striking surface and the
firing pin is located in the frame. When the
trigger is pressed and the hammer is released,
the hammer will strike the firing pin, driving it
into the primer. The firing pin will typically fea-
ture a return spring, which will drive the firing
pin backward as the action is unlocked.
Even newer single-action revolver designs will
utilize a part known as a transfer bar. The trans-
fer bar is used as a type of automated safety,
which prevents accidental discharge. Unlike
previous designs that could be dangerous if the
Figure 6: Separate hammer and firing pin. hammer were to fall prematurely, designs that
utilize a transfer bar are almost immune to ac-
cidental discharge.
Single-action revolvers that utilize a transfer bar
Early single-action revolvers utilize a hammer
will typically feature a lug on the frame or a re-
that features an integral firing pin on its striking
cess on the hammer’s face that will prevent the
surface. When the trigger is pressed and begins
contact of the hammer and firing pin. When the
to rotate around the trigger pin/screw, the sear
trigger is pressed and begins to rotate around
surface of the trigger will slide across the ham-
the trigger pin/screw, the transfer bar, which is
mer’s hooks and free the hammer’s movement.
linked to or activated by the trigger, will begin
The hammer (driven by the hammer spring)
to rise into the path of the hammer. The transfer
will rotate around the hammer pin and the in-
bar will move completely in front of the hammer
tegral firing pin will contact the primer, firing
before the hammer begins to move forward. The
the cartridge.

Figure 7: Single-action revolver transfer bar assembly.

98
 Figure 8: A single-action revolver’s unlocking step.

hammer will strike the transfer bar, which will bar and firing pin. After you have replaced the
strike the firing pin and eventually the primer. parts (or cleaned the action), you will need to
If the hammer were to fall before the trigger is perform a function and safety check, followed
pressed (because of wear or parts breakage), the by a test fire.
hammer would strike the lug on the frame and
not contact the firing pin. Single-Action Revolver Unlocking Problems
If any part of the FCG were to become broken, The next type of malfunction that you may expe-
damaged, or worn, the revolver may experience rience would be a failure to unlock. The unlock-
failures to fire. The most likely cause of a fail- ing step of a single-action revolver occurs after
ure to fire would be a worn or broken hammer the cartridge has been fired and the trigger can
spring or a damaged hammer. If the hammer reset. As the trigger moves forward (driven by
spring is worn, it will not produce enough force the trigger return spring), linkage connected to
to cause an adequate strike against the primer. the cylinder stop will pull it downward (against
If the spring, strut, hammer or transfer bar is the cylinder stop spring), out of the path of the
broken, it may fail to contact the firing pin at cylinder. The cylinder is now unlocked and the
all. Another cause of a failure to fire is a broken, action is ready to feed, lock, and fire once more.
damaged, or worn firing pin. Excessive dirt and If any part of a single-action revolver that con-
debris inside the action may also lead to a fail- trols unlocking is excessively dirty or worn, or
ure to fire due to the extra friction in the action any parts are broken or damaged, it could cause
slowing the FCG parts. the cylinder to fail to unlock. If the trigger or
Repairing failure to fire malfunctions with its linkage is broken or damaged, it may fail to
single-action revolvers is as simple as replac- drive the cylinder stop downward. If either the
ing the broken, damaged, or worn FCG parts trigger return or cylinder stop spring is worn, it
or thoroughly cleaning the action. This includes may fail to drive the respective parts and cause a
the hammer, strut and hammer spring, transfer failure to unlock.

99
 ejector rod that is used to push the empty car-
tridges from each individual chamber.
Once all the rounds have been fired, the op-
erator must set the hammer to half-cock and
open the loading gate so that he/she can begin
to extract/eject the empty cases. Once the first
chamber is aligned with the loading gate, the
operator depresses the ejector rod by the ejector
rod thumbpiece. The ejector rod will enter the
front of the empty case and drive it out of the
back of the cylinder. A return spring will drive
the ejector rod back into its resting position.
The operator must rotate the cylinder around
Figure 9: The extraction/ejection step of a single-action the base pin until the next chamber is aligned
revolver. with the loading gate. The operator must de-
press the ejector rod on each individual chamber
until the cylinder is empty.
If the ejector rod were to become broken, damaged,
Repairing unlocking malfunctions with single-
or worn, it could lead to a failure to extract/eject.
action revolvers is as simple as replacing the
The ejector return spring could lead to a failure
broken, damaged, or worn parts. This includes
to extract/eject if it were to become jammed in
the trigger, cylinder stop, linkage and springs.
the ejector rod channel/housing. Another cause
You will need to perform a function and safety
of a failure to extract/eject would be excessively
check once you have replaced the parts.
dirty or roughly machined chambers.
Single-Action Revolver Extracting and Repairing failure to extract/eject malfunctions
Ejecting Problems is as simple as replacing the broken, damaged,
Continuing through the COO, the next type or worn parts or assemblies. This includes the
of malfunction that may occur would be a fail- ejector rod assembly and return spring. If the
ure to extract and eject. With revolvers, the ex- chambers are roughly machined, you will need
traction and ejection steps are combined into a to polish the chambers as outlined earlier in this
single step. The single-action revolver does not guide. Once the chambers have been polished,
even utilize a traditional extractor, but rather an you will need to clean and lightly oil them.

Figure 10: The first stage of the feeding step of a double-action revolver.

100
 Figure 11: The second stage of the feeding step of a double-action revolver.

DOUBLE-ACTION REVOLVERS the operator closes the cylinder into the frame
until it is trapped by the cylinder release. This is
The double-action revolver design can be slight- the end of the first stage of the loading process.
ly more difficult to diagnose because of the in-
Once the cylinder has been loaded and locked
creased number of parts and slightly more com-
into the frame, the second stage of the feeding
plex action. The double-action revolver differs
process begins. This second stage of the process
from the single-action design in that the ham-
is semi-automated and is activated when the
mer can be cocked either by pressing the trigger
operator either cocks the hammer or presses the
or manually by the operator, unlike the single-
trigger (while the hammer is down). As the op-
action design, which can only be cocked manu-
erator moves the hammer back and down into
ally. The first stage of the feeding process will
the cocked position, linkage on the hammer
also differ slightly.
will activate the hand assembly (driving it up
Double-Action Revolver Feeding Problems and forward under spring force), which will act
upon the ratchet, causing the cylinder to rotate
Beginning with the feeding step in the COO,
clockwise around the crane/yoke and bringing
the first type of malfunction(s) a double-action
the first chamber into alignment with the barrel.
revolver action can experience would be failures
Simultaneously, the cocking of the hammer will
to feed. Like the single-action, the feeding step
also force the trigger to drive the cylinder stop
of a double-action revolver is a two-phase pro-
upward, locking the cylinder into alignment
cess that involves both the action and the op-
with the barrel. Pressing the trigger produces
erator. The first stage of the feeding step of a
the same results as manually cocking the ham-
double-action revolver involves depressing the
mer. This is the end of the second stage of the
cylinder release button. This frees the cylinder
feeding process.
and allows it to swing away from the frame on
a part called the crane/yoke. Once the cylinder Because the feeding step of a double-action re-
has swung outward, away from the frame, the volver involves two separate stages, you must
chambers are fully exposed and ready to load. diagnose each stage separately. Beginning with
The operator will load each chamber until the the first stage, if the leading edge of the cham-
cylinder is full. Once the chambers are loaded, ber is burred or does not feature a chamfer, it

101
may cause the cartridge to catch the edge of the cylinder rotates slightly and you hear and feel
chamber. If the cylinder release assembly is bro- the cylinder stop, you have a timing issue.
ken or damaged, it may fail to release the cylin- Once you have diagnosed the feeding problem,
der from the frame. repairing feeding issues with a double-action re-
During the second stage of a double-action re- volver is as simple as replacing the broken, dam-
volver’s feeding step, if the hammer, hand assem- aged, or worn parts and assemblies. If the fire-
bly (including spring), or ratchet is damaged or arm is excessively dirty, you will need to clean
broken, it will prevent the cylinder from rotating the parts/assemblies that are causing the mal-
and aligning the next chamber with the barrel. If functions. This includes the cylinder, chambers,
either the hand or ratchet is excessively worn, it and crane/yoke, as well as the ratchet. Other
will cause a timing issue. Either situation can be parts that may need replacement would include
extremely dangerous. There is a possibility that the hammer/trigger and hand. Once the parts
the hammer can strike the primer of a cartridge have been replaced, you will need to perform a
that is slightly misaligned with the barrel. function and safety check of the firearm to ver-
If you suspect the hand or ratchet is broken, ify there is no timing issue. If the chambers do
damaged, or worn, you can verify by watch- not feature a bevel/chamfer along their leading
ing and checking the cylinder. With an empty edge, you will need to form one. Once the fire-
firearm, slowly set the hammer to the cocked arm has been function and safety checked, you
position (or begin to press the trigger). Watch will need to test fire it.
the cylinder as it rotates around the yoke and Double-Action Revolver Locking Problems
carefully listen for a “click” as the cylinder stop
engages the cylinder before the hammer is fully The next type of malfunction you may experi-
cocked. Once the hammer is fully cocked, check ence with revolver actions would be a failure
the cylinder to verify it is locked in place. If the to lock. The locking step of a double-action

Figure 12: Parts of a double-action revolver locking assembly.

102
 Figure 13: Double-action revolver cocking function in single-action.

revolver is accomplished when the hammer is If any part of the locking assembly or parts
set to the cocked position or when the hammer that drive the locking assembly become bro-
has nearly reached the end of its travel when ken, damaged, or worn, the firearm may fail to
the trigger is pressed. In single-action, as the lock. This includes the hammer, trigger, hand,
hammer travels rearward, driving the hand into spring, cylinder stop, ratchet, or cylinder. If the
the ratchet and causing the cylinder to rotate hammer, trigger, or hand is broken, damaged,
around the crane/yoke, the hammer will also or worn, it may fail to drive the cylinder or cyl-
drive the trigger so that the sear surface of the inder stop or fail to drive the parts throughout
trigger engages the hammer’s hooks. As the their full travel. If the cylinder stop notch or
trigger moves into position to trap the hammer, the cylinder stop is damaged or worn, it may
it will drive the cylinder stop upward (through cause play in the cylinder or may allow the cyl-
linkage and spring force) so that it can engage inder to unlock. If the spring that drives the
the stop notch in the cylinder. In double-action, cylinder stop is worn or damaged, it may also
as the trigger is pressed, it will drive the hammer allow the cylinder to unlock.
into the cocked position and (simultaneously) Repairing locking malfunctions with double-
drive the hand and cylinder stop. action revolvers is as simple as replacing the
While the cylinder is rotating around the crane/ broken, damaged, or worn parts. This includes
yoke (bringing the next chamber into align- the hammer, trigger, hand, cylinder stop or the
ment), the cylinder stop moves upward, engag- cylinder itself. Once the damaged parts have
ing a ramped section (lead) just ahead of the been replaced, you will need to perform a func-
stop notch. The stop will ride the lead into the tion and safety check, as well as check the tim-
stop notch and arrest the cylinder’s movement, ing. If you must replace the cylinder, you will
aligning the chamber with the barrel. The stop also have to perform a headspace check.
should engage the notch and lock the cylinder
slightly before the hammer is fully cocked.

103
Figure 14: Double-action revolver cocking function in double-action.

Figure 15: Double-action revolver ejector rod and ejector assembly.

104
Double-Action Revolver Cocking Problems surface into the path of the hammer’s hooks. If
Continuing through the COO, the next type the hammer strut is broken or damaged, it may
of malfunction you may encounter would be a not allow the hammer to move far enough back
failure to cock. The cocking step of a double-ac- to reach the cocked position.
tion revolver can be accomplished in one of two Repairing failure to cock malfunctions is as
ways: manually by the operator (single-action) simple as replacing broken, damaged, or worn
and automatically by pressing the trigger (dou- FCG parts. This includes the hammer, strut,
ble-action). While the hammer does not techni- hammer spring, trigger and trigger springs. You
cally rest in the cocked position while being ma- may want to replace both sear surfaces (the trig-
nipulated in double-action, it will momentarily ger and hammer) to ensure there are no further
reach the cocked position before immediately complications from new parts working against
dropping. Different parts control each method old parts. In some instances, the sear surfaces
of cocking, so you will need to understand each can be dressed (outlined earlier in this guide)
process. When the operator drives the hammer to try to save hard-to-find parts. Once the parts
backward and down (against the pressure of the have been replaced or repaired, thoroughly clean
mainspring) into the cocked position, the ham- the FCG and lightly lubricate all contact points.
mer’s hooks will begin to act upon a tang at the Perform a function and safety check before you
rear of the trigger, which will force the trigger perform a final test fire to ensure everything
around the trigger pin/screw. The trigger spring functions correctly.
(or rebound slide) will drive the trigger’s sear sur-
face, which is typically located on a tang on the Double-Action Revolver Firing Problems
rear of the trigger, into the path of the hammer’s Moving through the COO, the next type of
sear hooks, arresting the hammer’s movement. malfunction that may occur would be a failure
When the operator presses the trigger, a tang at to fire. Like the single-action revolver, the firing
the rear of the trigger (where the sear surfaces sequence of the double-action revolver will vary
are located) acts upon a part of the hammer as- slightly with design. With some designs, the
sembly called the sear. As the trigger rotates firing pin is located on the hammer, and with
around the trigger pin/screw, the rear tang of the others it is in the frame. Some designs also use
trigger will push upward against the sear, which transfer bars and others use hammer blocks.
will drive the hammer back and down into the With designs that utilize a firing pin in the
cocked position. The hammer will only be in the hammer, when the operator presses the trigger
cocked position momentarily because as the trig- and drives/releases the hammer, the hammer’s
ger continues rearward through its stroke, it will firing pin will contact the primer directly and
release the hammer once it has reached full-cock. fire the cartridge. Newer variants of this design
The sear is powered by a spring, which allows it will incorporate a hammer block that will pre-
to pivot out of the way when the trigger is reset. vent the hammer from falling prematurely or
If any part of the FCG is broken, damaged, or unintentionally when the trigger has not been
worn, the revolver may fail to cock. If either sear pressed. With designs that utilize a firing pin in
surfaces on the trigger or hammer are broken or the frame, when the operator presses the trigger
damaged, the hammer may fail to cock. If the and drives/releases the hammer, the hammer will
sear surfaces are excessively worn, the hammer fall onto the firing pin in the frame and drive it
may cock temporarily and fall unintentionally if into the primer. Variants of this design will use a
bumped or tapped. If the trigger spring is dam- transfer bar between the hammer and firing pin
aged or worn, it may fail to drive the trigger’s sear

105
to prevent accidental discharge if the hammer you will need to perform a function and safety
were to fall when the trigger is not being pressed. check, followed by a test fire.
If any part of the FCG were to become broken, Double-Action Revolver
damaged, or worn, the revolver may experience Unlocking Problems
failures to fire. The most likely cause of a fail-
ure to fire would be a worn or broken hammer The next type of malfunction that you may expe-
spring or a damaged hammer. If the hammer rience would be a failure to unlock. The unlock-
spring is worn, it will not produce enough force ing step of a double-action revolver occurs after
to cause an adequate strike against the primer. If the cartridge has been fired and the trigger can
the spring, strut, hammer or transfer bar is bro- reset. As the trigger moves forward (driven by
ken, it may fail to contact the firing pin at all. If the trigger return spring), linkage connected to
the hammer block is broken or damaged, it may the cylinder stop will pull it downward (against
fail to clear the path of the hammer and prevent the cylinder stop spring), out of the path of the
it from contacting the primer. Another cause of a cylinder. The cylinder is now unlocked and the
failure to fire is a broken, damaged, or worn firing action is ready to feed, lock, and fire once more.
pin. Excessive dirt and debris inside the action If any part of a double-action revolver that con-
may also lead to a failure to fire due to the extra trols unlocking is excessively dirty or worn, or
friction in the action slowing the FCG parts. any parts are broken or damaged, it could cause
Repairing failure to fire malfunctions with the cylinder to fail to unlock. If the trigger or
double-action revolvers is as simple as replac- its linkage is broken or damaged, it may fail to
ing the broken, damaged, or worn FCG parts drive the cylinder stop downward. If either the
or thoroughly cleaning the action. This includes trigger return or cylinder stop spring is worn, it
the hammer, strut and hammer spring, transfer may fail to drive the respective parts and cause a
bar, hammer block, and firing pin. After you failure to unlock.
have replaced the parts (or cleaned the action),

Figure 16: Cylinder gap.

106
Repairing unlocking malfunctions with double-
action revolvers is as simple as replacing the
broken, damaged, or worn parts. This includes
the trigger, cylinder stop, linkage and springs.
You will need to perform a function and safety
check once you have replaced the parts.

Double-Action Revolver Extracting and

Ejecting Problems
Continuing through the COO, the next type of
malfunction that may occur would be a failure
to extract and eject. Like the single-action re-
volver, the double-action revolver combines the
extraction and ejection steps into one sequence.
The double-action revolver does not even fea-
ture a traditional ejector.
Once all the cartridges have been fired, the op-
erator depresses the cylinder release and swings
the cylinder out, away from the frame to expose
the chambers. The operator will then depress
the extractor rod, which will drive the extractor
into the rim of the cartridge cases. The extrac-
tor will push all the cases from the chambers si-
multaneously. Using gravity, all the empty cases Figure 17: Pressure release from cylinder gap.
will fall from the chambers. The extractor return
spring will force the extractor back into the cyl-
inder in preparation for loading.
If the extractor rod or extractor were to become
broken, damaged, or worn, it could lead to a fail- CYLINDER GAP
ure to extract/eject. The extractor return spring
could lead to a failure to extract/eject if it were There is one more issue that may arise with both
to become jammed in the crane/yoke. Another single- and double-action revolvers. Regardless
cause of a failure to extract/eject would be ex- of action design or type, there must be a small
cessively dirty or roughly machined chambers. amount of clearance between the cylinder and
Repairing failure to extract/eject malfunctions barrel of a revolver for proper function. This
is as simple as replacing the broken, damaged, allows the cylinder to move freely without
or worn parts or assemblies. This includes the binding. This space is called the cylinder gap.
extractor rod, extractor assembly, and return Depending on design and caliber, the gap may
spring. If the chambers are roughly machined, range from .003 in. to .013 in.
you will need to polish the chambers as outlined When the cartridge is discharged and the bullet
earlier in this guide. Once the chambers have is forced from the case and through the throat
been polished, you will need to clean and lightly of the cylinder, it must jump from the cylinder,
oil them.

107
through the gap, and into the forcing cone of factory specs. When the new barrel is installed,
the barrel. When the projectile passes from the it must be screwed down until its shoulder bot-
cylinder to the barrel, a considerable amount of toms out against the frame. If the barrel is not
hot, high pressure gas is released from the gap. indexed correctly after torqueing, you will need
If the cylinder gap were to grow beyond the man- to cut the shoulder back until the barrel is in-
ufacturer’s original specifications, it could lead dexed correctly. Once the barrel is indexed, you
to a dangerous situation where large amounts of will need to check the cylinder gap. If the gap is
hot, high pressure gas and possibly fragments of too small, you will need to cut the breech face
bullets can injure the operator. If the gap is too of the barrel to the correct size. If the gap is too
large, there is a chance for misalignment, which large, you will need to cut the shoulder back and
could lead to the bullet shaving across the in- start the process over.
side edge of the barrel’s forcing cone. Over time, A least likely fix may be as simple as replac-
the cylinder’s contact with the frame and barrel ing the cylinder or ratchet assembly. Because of
can lead to enough wear to open the gap (which manufacturer variances, you may be able to find
could also lead to a headspace issue). a slightly longer cylinder that will close the gap.
Often, the only real fix to an excessive cylinder Anytime you replace the cylinder you will need
gap is to replace and re-index a new barrel. This to perform a headspace check. After either the
involves removing the old barrel from the frame barrel or cylinder is replaced, you will need to
and machining the new barrel so that it is within perform a function and safety check as well as
a test fire.

108
 REVOLVER ACTION TROUBLESHOOTING
Malfunction Possible Causes Solution

Failure to Feed 1. Broken, damaged, or worn 1. Replace broken, damaged, or

parts including the cylinder, worn parts.
ratchet, hammer, hand, and 2. Polish, then clean and oil the
cylinder release or springs. chamber. Recut the chamber
2. A roughly machined or under- to SAAMI specs.
sized chamber(s).

Failure to Lock 1. Broken, damaged, or worn 1. Replace broken, damaged, or

parts, including the hammer, worn parts.
trigger, cylinder stop, spring or
cylinder.

Failure to Cock 1. Broken, damaged, or worn 1. Replace worn or damaged

sear surfaces. Broken or dam- parts. Some sear surfaces can
aged FCG parts, including the be dressed and polished.
strut and springs.

Failure to Fire 1. Broken, damaged, or worn 1. Replace broken, damaged, or

FCG parts, including the ham- worn parts.
mer, strut, spring, transfer bar 2. Thoroughly clean and lightly oil
and firing pin. the action.
2. Excessive dirt and debris
inside the action.

Failure to Unlock 1. Broken, damaged, or worn 1. Replace broken, damaged, or

unlocking parts or assemblies, worn parts.
including the trigger, return
spring, cylinder stop and cylin-
der stop spring.

Failure to With Single-Action Revolvers: With Single-Action Revolvers:

Extract/Eject 1. Broken, damaged, or worn 1. Replace broken, damaged, or
ejection parts, including the worn parts.
ejector rod and return spring. 2. Polish and lightly oil the cham-
2. Roughly machined chambers. bers.

With Double-Action Revolvers: With Double-Action Revolvers:

1. Broken, damaged, or worn 1. Replace broken, damaged, or
extraction parts, including the worn parts.
extractor rod, extractor and 2. Polish and lightly oil the cham-
return spring. bers.
2. Roughly machined chambers.

109
NOTES
 Chapter 5 - Troubleshooting Blowback Actions
TROUBLESHOOTING BLOWBACK ACTIONS 113
Blowback Action Troubleshooting 124
112
 Troubleshooting
Blowback Actions
Unlike all the previous actions that have been
discussed, the blowback action is completely re-
liant on ammunition and operator technique for
proper function. The blowback design also pres-
ents unique challenges because the action does
not truly lock like every other action design. To
make things even more complicated, there are
many variants of the blowback design that use
various mechanical means to try to delay the
“unlocking” or opening of the action. The two
blowback action types are straight blowback
and delayed blowback.
The major difference between the two blowback
actions occurs during the locking and unlock-
ing stages; feeding, cocking, firing, extracting

113
 Figure 1: The feeding step of a tubular magazine-fed blowback action.

and ejecting will all be similar. With straight improper shooting technique can both lead to
blowback actions, the only things that hold the malfunctions with blowback actions. Once am-
breech closed during discharge are the weight of munition and operator error are ruled out, you
the bolt/slide and the inertia of the action/recoil can focus on the firearm itself.
spring. The straight blowback action is designed
for low power cartridges like rimfire and small Blowback Action Feeding Problems
centerfire pistol rounds. With delayed blowback Beginning with the feeding step in the COO,
actions, various mechanical means, such as roll- the first type of malfunction(s) a blowback ac-
ers, levers, gas, friction or toggles, as well as the tion firearm can experience would be failures
weight of the parts and inertia of the action/ to feed. Because of the function of the action,
recoil spring, are used to slow the “unlocking” blowback firearms are always magazine-fed.
or opening of the breech after discharge. The Depending on the specific model, the firearm
delayed blowback action is designed for more may be fed by a fixed (tubular) magazine or by
powerful cartridges, such as centerfire bottle- a fixed or detachable box magazine. Each spe-
neck rifle rounds. cific feed type will feature a different feeding se-
Because the breech does not lock and the only quence and will have different parts to diagnose.
thing driving the action is the energy that is cre- Regardless of feed type, the initial step in the
ated by the cartridge, diagnosing blowback ac- feeding process of blowback firearms is the
tions can be tricky. Underpowered cartridges or same. With a fully loaded magazine, an empty

114
chamber and a closed breech, the operator ma- forward until it has bottomed out against the
nipulates the bolt/charging handle or slide. As breech face of the barrel, which is fixed in place.
the operator drives the bolt/charging handle/ With box magazine-fed (fixed and detach-
slide to the rear of the action, it will begin to able) blowback actions, as the action continues
compress the action/recoil spring. rearward, the bolt/slide will pass over the top
With tubular magazine-fed blowback actions, cartridge in the magazine (pushing it down-
as the action continues rearward, the bolt will ward slightly) and continue rearward until
trip the elevator/lifter, which will begin to move it has reached the end of its rearward stroke.
downward in preparation for feeding. As the Once the bolt/slide has reached the end of its
bolt continues rearward, either the bolt or eleva- rearward travel, the action/recoil spring will be
tor/lifter will trip a cartridge release/stop that fully compressed and ready to drive the action
will allow one round from the magazine to enter forward again.
the breech and onto the elevator lifter. Once the With the action/recoil spring fully compressed,
operator has reached the end of the bolt’s stroke, the operator releases the bolt/charging handle/
the action/recoil spring will be fully compressed slide, allowing the action to move forward under
and ready to drive it forward. spring force. As the bolt/slide moves forward, a
With the action/recoil spring fully compressed, lug (typically the cocking lug) on the bottom of
the operator releases the bolt/charging handle, the bolt/slide will contact the head of the car-
allowing the action to move forward under tridge case and begin to drive it from the maga-
spring force. The action/recoil spring will drive zine. The bolt will continue forward, driving the
the bolt forward. As the bolt moves forward, it round from the magazine until it has bottomed
will trip the elevator/lifter and force it upward, out against the breech face of the barrel, which
bringing the cartridge into alignment with the is fixed in place.
bolt. As the bolt continues forward, it will begin Regardless of the feed device type, once the
to push the cartridge from the elevator/lifter and bolt/slide has bottomed out against the barrel,
drive it into the chamber. The bolt will continue the round has been fully fed into the chamber.
If any one of the parts that controls the feeding

Figure 2: The feeding step of a box magazine-fed blowback action.

115
step becomes broken, damaged, or worn, it only), bolt/slide, action/recoil spring and cham-
may lead to a failure to feed. This includes the ber. If you must replace the bolt/slide, you will
magazine (tubular or box) assembly, elevator/ need to perform a headspace check. If the issue
lifter (tubular magazine firearms only), the bolt/ is caused by a short or rough chamber, you will
slide, or the action/recoil spring assembly. If need to polish or recut the chamber to SAAMI
the magazine assembly is broken, damaged, or specs. If the chamber is excessively dirty, you
worn, it may allow too many cartridges into the will need to thoroughly clean and lightly lubri-
breech at once, or may fail to even feed a single cate the chamber. Once you have replaced parts,
round. If the elevator/lifter is broken, damaged, you will need to perform a function and safety
or worn, it may fail to raise the round into the check, followed by a test fire.
path of the bolt. If the lug on the bolt/slide is
broken, damaged, or worn, it may fail to drive Blowback Action Locking Problems
the round from the magazine or may cause The next type of malfunction you may experi-
misalignment of the round as it moves toward ence with blowback action firearms would be a
the chamber. If the action/recoil spring assem- failure to lock. Because of the simplicity of the
bly is broken, damaged, or worn, it may fail to straight blowback design, the moment the bolt/
drive the bolt/slide with enough force to fully slide bottoms out against the barrel, the breech
chamber the cartridge. Two less likely (but still is fully “locked.” There is no locking lug engage-
possible) causes of a failure to feed would be a ment, no bolt turning, no locking mechanisms,
roughly machined or undersized chamber or ex- only the bolt/slide touching the barrel. The only
cessive dirt and debris. thing keeping the breech closed is the action/re-
Repairing failure to feed malfunctions with coil spring, even with designs that utilize a me-
blowback firearms is as simple as replacing the chanical means of delaying the breech’s opening.
broken, damaged, or worn parts. This includes When delayed blowback actions “lock,” all that
the magazine assembly (body, spring and follow- is holding the breech closed is the action/recoil
er), elevator/lifter (tubular magazine firearms spring. The delaying mechanism will “preload”

Figure 3: A locked straight blowback action.

116
as the action closes in preparation for discharge,
but does not technically lock. The delaying
mechanism only affects the unlocking step in
the COO, but can disturb the locking step if the
parts are malfunctioning.
If any part of the assemblies that control locking
were to become broken, damaged, or worn, the
action may fail to lock. The primary reason any
blowback action would fail to lock would be a
broken, damaged, or worn action/recoil spring
assembly. If there is an issue with the action/
recoil spring assembly, it may fail to drive the
bolt/slide with enough force to feed the round
into the chamber and bottom out against the
barrel. The next possible cause of a locking mal-
function with blowback firearms would be ex- Figure 4: Blowback action cocking.
cessive dirt and debris in the action and cham-
ber. Because straight blowback actions are often
chambered in rimfire calibers, which typically
produce a lot of fouling, they are more likely
to experience a malfunction caused by exces- Blowback Action Cocking Problems
sive friction. Another cause of a failure to lock Continuing through the COO, the next type of
would be the extractor. If the extractor is broken malfunction you may encounter would be a fail-
or damaged, it may fail to jump over the rim of ure to cock. The cocking step of a blowback fire-
the cartridge and the breech may not fully close. arm occurs automatically when the action cycles
With delayed blowback actions, if any part or after a cartridge has been discharged. The cock-
assembly that is used to slow the action becomes ing step also occurs when the operator charges
broken, damaged, worn, or excessively dirty, it the firearm, loading the first cartridge into the
may create excessive friction in the action or empty chamber. With blowback actions, the
cause the action to seize. This includes roller, le- cocking step may occur with either a hammer
ver and toggle assemblies. Blowback actions are or striker. An addition of a part known as the
also susceptible to locking malfunctions caused disconnector will also introduce another factor
by rough or undersized chambers. when diagnosing issues.
Repairing failure to lock malfunctions with With hammer-fired models, when the op-
blowback firearms is as simple as replacing the erator loads the firearm in preparation for fir-
broken, damaged, or worn parts. This includes ing, as they pull the charging handle/slide to
the action/recoil spring assembly, extractor or the rear of the action, an integral cocking lug
delaying assemblies. If the action and chamber on the underside of the bolt/slide will contact
are excessively dirty, you will need to thoroughly the striking face of the hammer and begin to
clean and lightly lubricate the action and cham- drive it back and downward into the cocked
ber. If the chamber is rough or undersized, you position. Simultaneously, if the operator is still
will need to polish or recut the chamber. holding the trigger, the bolt slide will trip the

117
disconnector, allowing it to trap the hammer. If cycle and cock the hammer/striker. This cycle
the operator has released the trigger, the ham- will continue until the magazine is empty.
mer will be trapped by the sear or trigger, fully If any part or assembly that controls cocking
cocked and ready to fire. The bolt/slide will becomes broken, damaged, or worn, it may lead
continue rearward until it reaches the end of its to a failure to cock. Because of the design of the
rearward stroke and slams forward under ac- blowback action, ammunition and the operator
tion/recoil spring force. can both contribute to cocking malfunctions in
With striker-fired models, when the operator the form of short-stroking. Short-stroking oc-
loads the firearm, as the action moves back- curs with blowback actions when the cartridge
ward, the bolt/slide will carry the striker with fails to produce enough energy to drive the ac-
it. Simultaneously, if the operator is still holding tion completely through its stroke. It will also
the trigger, the bolt/slide will trip the discon- occur when the operator fails to hold the fire-
nector, allowing the sear to move into position arm with enough force to prevent it from recoil-
to trap the striker. If the operator has released ing excessively, causing the energy used to cycle
the trigger, the sear will already be in position, the action to dissipate.
ready to trap the striker. The bolt/slide will con- Once you have ruled out ammunition and op-
tinue rearward until it reaches the end of its erator error as possible causes for malfunction,
rearward stroke and slam forward under action/ you can focus on the remainder of the action.
recoil spring force. As the bolt/slide travels for- The most likely cause of a failure to cock mal-
ward, the striker will be trapped by the sear, fully function would be damage or wear to the FCG
cocked and ready to fire. parts, including the hammer/striker, hammer
When the operator fires the round, the energy strut, trigger, sear, disconnector and respec-
created during discharge will drive the bolt/slide tive springs. If the sear surfaces are worn or
rearward once more, cocking the hammer/strik- damaged, the hammer/striker may only cock
er. Each time a round is fired, the action will temporarily before prematurely falling. If the

Figure 5: Blowback action FCG parts.

118
hammer strut or hammer or striker spring is The firing pin will lunge forward, striking the
damaged or broken, the hammer/striker may primer and discharging the round. If the fire-
fail to cock at all. arm utilizes a striker assembly, when the opera-
A less likely but still possible cause of a failure tor presses the trigger, the sear will release the
to cock would be the action/recoil spring. If the striker, allowing it to lunge forward and strike
action/recoil spring is broken or damaged, it the primer.
may not allow the action to travel far enough to If any part of the FCG becomes broken, dam-
the rear of its travel to fully cock the hammer/ aged, or worn, the firearm may experience a fail-
striker. Excessive dirt and debris inside the ac- ure to fire. The most likely cause of failures to
tion can also lead to a failure to cock if the foul- fire with blowback actions would be broken or
ing produces enough friction to slow the cycling damaged firing pins/strikers or worn hammers
action. A dirty or roughly machined chamber or striker springs. If the firing pin or striker
can also create enough friction to slow the ac- is damaged or broken, it may fail to create an
tion and cause a failure to cock. indentation on the primer or may make an in-
Repairing failure to cock malfunctions is as sim- dentation that is too shallow. If the hammer or
ple as replacing broken, damaged, or worn FCG striker spring is worn or broken, it may not drive
parts. This includes the hammer/striker, strut, the hammer/striker quickly enough to strike the
hammer spring, sear, sear spring, disconnector, primer hard enough.
disconnector spring, trigger and trigger springs. A few less likely but still possible causes would
You may want to replace both sear surfaces (the be long chamber or long headspace or excessive
sear and hammer/striker) to ensure there are no dirt and debris inside the FCG. Because of the
further complications from new parts working allowable tolerances of the chamber, firing pin/
against old parts. In some instances, the sear striker and cartridge, if the chamber is on the
surfaces can be dressed (outlined earlier in this long side and the ammunition is on the short
guide) to try to save hard-to-find parts. Once side, the firing pin/striker may not be able to
the parts have been replaced or repaired, thor- create a deep enough depression in the primer.
oughly clean the FCG and lightly lubricate all If the FCG is excessively dirty, it may create
contact points. Perform a function and safety enough friction to slow the hammer and firing
check before you perform a final test fire to en- pin or striker enough to create a light strike.
sure everything functions correctly. Repairing failure to fire malfunctions with
Blowback Action Firing Problems blowback firearms is as simple as replacing the
broken, damaged, or worn parts. This includes
Moving through the COO, the next type of the hammer/striker, hammer spring, striker
malfunction that may occur would be a failure spring, firing pin or other parts of the FCG that
to fire. Like other action types, failure to fire may interfere with the firing step. If the FCG
malfunctions with blowback actions can be con- is excessively dirty, you will need to thoroughly
tributed to one assembly: the FCG. The firing clean and lightly lubricate the parts. If the is-
step will vary slightly depending on if the sys- sue is caused by a long chamber, you may need
tem is hammer- or striker-fired. to replace the barrel or the bolt slide. If you do
If the firearm utilizes a hammer assembly, when replace the barrel or bolt/slide, you will need
the operator presses the trigger and releases the to perform a headspace check. Once you have
hammer, it will fall and contact the firing pin. replaced the parts, you will need to perform a
function and safety check, followed by a test fire.

119
 Figure 6: Roller delayed action opening.

Blowback Action Unlocking Problems If the firearm utilizes a delayed blowback action,
The next type of malfunction that you may the unlocking step may be difficult to diagnose
experience would be a failure to unlock. If the because of the added complexity of the delay-
firearm utilizes a straight blowback action, the ing device. Because the devices used to delay the
unlocking step is extremely simple. The mo- “unlocking” or opening of the breech can vary
ment the cartridge is discharged, the high pres- greatly, diagnosing issues may be challenging
sure gas that pushes the bullet from the firearm if you do not fully understand how the action
begins to push backward against the cartridge works. For the purposes of this guide, we will
case. The pressure begins to drive the case rear- focus on the three most popular means of action
ward, which forces the bolt/slide back. The mo- delaying: roller, lever, and gas.
ment the bolt/slide and barrel are separated, the With roller delayed actions, when the round is
breech is “unlocked” or open. discharged and the case begins to push against
the bolt, the bolt will begin to move backward.
As the bolt moves backward, it will contact the

120
 Figure 7: Lever delayed action opening.

rollers, which will force the bolt carrier back at bottom out against a leverage surface or the re-
a greater velocity than the bolt, slightly delaying ceiver. The lever will begin to rotate, driving the
the opening of the breech. As the bolt carrier long arm (effort arm) into the bolt carrier and
moves backward, after a short distance, the car- forcing it backward at a greater velocity than the
rier will begin to pull the bolt with it, “unlock- bolt, slightly delaying the opening of the breech.
ing” the breech. As the bolt carrier moves backward, after a short
With lever delayed actions, when the round is distance the carrier will begin to pull the bolt
discharged and the case begins to push against with it, “unlocking” the breech.
the bolt, the bolt will begin to move back- With gas delayed actions, when the round is
ward. As the bolt moves backward, it will be- discharged and the case begins to push against
gin to move the lever with it. Almost instantly, the slide, the slide will begin to move backward.
the short arm (resistance arm) of the lever will A port just ahead of the chamber will bleed high

121
pressure gas into a chamber under the barrel. Repairing unlocking malfunctions with blow-
The tapped gas will act upon a piston that is back firearms is as simple as replacing the bro-
affixed to the slide, which will delay the slide’s ken, damaged, or worn parts. This includes the
movement, slightly delaying the opening of the action/recoil spring, barrel, bolt/slide or delay-
breech. Once the bullet has exited the muzzle, ing device, if applicable. If the chamber is rough
the pressure inside the bore and chamber will or excessively dirty, you will need to polish and
dissipate, allowing the slide to move backward thoroughly clean and lightly lubricate it. If you
with no (extra) resistance. must replace the barrel or bolt/slide, you will
If any part or assembly that is associated with need to perform a headspace check. After you
unlocking becomes broken, damaged, or worn, have replaced any part, you will need to per-
the firearm may fail to unlock. This includes form a function and safety check, followed by
the action/recoil spring, chamber, bolt/slide and a test fire.
delaying device, if applicable. The most likely Blowback Action Extracting Problems
cause of an unlocking malfunction with blow-
back firearms would be a damaged or broken ac- Continuing through the COO, the next type of
tion, or recoil spring. If the spring or spring as- malfunction that may occur would be a failure
sembly is damaged, it may not allow the breech to extract. Like other steps in a blowback ac-
to open. If the chamber is roughly machined tion’s COO, the extracting step can be affected
or excessively dirty, it may create so much fric- by ammunition and improper operator tech-
tion between the empty case and chamber walls nique. Once ammunition or operator error has
that it dissipates the energy trying to force the been ruled out, you can focus on the firearm.
case and action backward. If the bolt or slide When the cartridge is discharged and the high
becomes damaged or broken, it may create so pressure gas in the chamber and bore begin to
much friction within the receiver or along the push against the bolt/slide, an extractor affixed
slide rails that it does not unlock after discharge. to the bolt/slide will immediately begin pulling
If the action utilizes a device to delay the ac- the case from the chamber. As the bolt/slide
tion’s opening, or if any part or assembly of the begins moving backward, the extractor’s claw
delaying device is broken, damaged, or worn, it will grab the rim of the empty case. As the high
may cause the action to bind and fail to open. pressure gas continues to drive the bolt/slide

Figure 8: Blowback action extracting.

122
 you will need to polish the chamber and thor-
oughly clean and lightly lubricate it. Once you
have replaced parts, you will need to perform a
function and safety check.

Blowback Action Ejecting Problems

The last type of malfunction that may occur
would be a failure to eject. Like other steps of
a blowback action’s COO, the ejection step can
be affected by ammunition and improper opera-
tor technique. Once ammunition and operator
error have been ruled out as a cause of ejection
malfunctions, you can focus on the remainder of
the firearm.
After discharge, as the action moves rearward,
Figure 9: Blowback action ejecting. the extractor will pull the empty case into the
ejector. As the empty case contacts the ejector,
it will begin to rotate around the extractor and
out of the ejection port. Most blowback actions
utilize an ejector that is affixed to the frame be-
cause a sprung or powered ejector (located in
the bolt face or slide) would force the action out
rearward, it will continue to drag the empty case of battery and would not allow the breech to
from the chamber. close completely.
If any part or assembly that controls extracting If any part or assembly that controls ejecting
becomes broken, damaged, or worn, the firearm becomes broken, damaged, or worn, the firearm
may experience failure to extract. The most like- may experience failure to eject. The most likely
ly cause of extraction malfunctions would be a cause of a failure to eject would be the ejector
broken, damaged, or worn extractor or extractor itself. If the ejector is broken, damaged, or worn,
spring. If the extractor or spring is damaged or when the empty case impacts the ejector, it may
worn, it may not grab the rim of the case or may fail to exit the breech or become jammed in the
slip over the rim prematurely. If the action/recoil action. The firearm may also experience erratic
spring is broken or damaged, it may not allow the ejection and possibly eject cases directly at the
action to travel back far enough for the extrac- operator. If the action/recoil spring or assembly
tor to remove the case from the chamber. If the is damaged, it may not allow the action to travel
chamber is dirty or rough or the action is exces- far enough backward to complete ejection. If
sively dirty, it may create so much friction that the chamber is rough or excessively dirty, it may
the action does not complete its rearward stroke create so much friction that the action cannot
and fails to extract the case from the chamber. eject the case completely.
Repairing extraction malfunctions with blow- Repairing ejection malfunctions with blowback
back actions is as simple as replacing the broken, firearms is as simple as replacing the broken,
damaged, or worn parts. This includes the ex- damaged, or worn parts. This includes the ejector
tractor, extractor spring or action/recoil spring. and action/recoil spring. If the chamber is rough,
If the chamber is rough, you will need to polish you will need to polish and thoroughly clean it. If
the chamber and thoroughly clean and lightly the action or chamber is excessively dirty, you will
lubricate it. If the chamber is roughly machined, need to thoroughly clean and lightly lubricate it.

123
 BLOWBACK ACTION TROUBLESHOOTING
Malfunction Possible Causes Solution

Failure to Feed 1. Broken, damaged, or worn 1. Replace broken, damaged, or

feed parts, including the worn parts or assemblies.
magazine assembly, elevator/ 2. Polish, then clean and oil the
lifter, bolt/slide or action/recoil chamber. Recut the chamber
spring. to SAAMI specs.
2. A roughly machined or under-
sized chamber.
Failure to Lock 1. Broken, damaged, or worn ac- 1. Replace broken, damaged, or
tion/recoil spring assembly. worn parts or assemblies.
2. Excessive dirt and debris in the 2. Thoroughly clean and lightly
action and chamber. lubricate the action and cham-
3. Broken or damaged extractor. ber.

4. Broken or damaged delaying 3. Replace the extractor assem-

parts, including roller, lever and bly.
toggle assemblies. 4. Replace broken, damaged, or
5. A roughly machined or under- worn parts or assemblies.
sized chamber. 5. Polish, then clean and oil the
chamber. Recut the chamber
to SAAMI specs.
Failure to Cock 1. Broken, damaged, or worn 1. Replace worn or damaged
FCG parts, including the ham- parts. Some sear surfaces can
mer/striker, sear, disconnector, be dressed and polished.
trigger or springs. 2. Replace broken, damaged, or
2. Broken, damaged, or worn ac- worn parts.
tion/recoil spring assembly. 3. Thoroughly clean and lightly
3. Excessive dirt and debris in the lubricate the action.
action or chamber. 4. Polish, then clean and lightly
4. Roughly machined chamber. oil the chamber.

124
 BLOWBACK ACTION TROUBLESHOOTING
Malfunction Possible Causes Solution

Failure to Fire 1. Broken, damaged, or worn 1. Replace broken, damaged, or

FCG parts, including the worn parts.
hammer/firing pin, striker and 2. Replace the barrel or bolt/slide.
springs.
3. Thoroughly clean and lightly
2. Long chamber/headspace. lubricate the action.
3. Excessive dirt and debris in the
FCG.
Failure to Unlock 1. Broken or damaged action/re- 1. Replace broken, damaged, or
coil spring or bolt/slide. worn parts.
2. Excessively rough or dirty 2. Polish and thoroughly clean
chamber. and lightly lubricate the cham-
3. Broken, damaged, or worn ber.
delaying assembly. 3. Replace broken, damaged, or
worn parts.
Failure to Extract 1. Broken, damaged, or worn 1. Replace broken, damaged, or
parts including the extractor, worn parts.
extractor spring or action/recoil 2. Polish and thoroughly clean
spring. and lightly lubricate the cham-
2. Excessively rough or dirty ber.
chamber.

125
126
 Chapter 6 - Troubleshooting Recoil-Operated Actions
TROUBLESHOOTING RECOIL-OPERATED ACTIONS 129
Inertia-Operated, Long Recoil and Short Recoil Actions 130
Inertia, Long and Short Recoil Actions 134
Recoil-Operated Action Troubleshooting 145
128
 Troubleshooting
Recoil-Operated
Actions
Like the blowback action, recoil-operated
firearms rely on the energy created by the
discharging cartridge to cycle the action. But
unlike the blowback action, recoil-operated
firearms utilize a locking breech. Recoil-
operated actions also are not driven directly
by the pressure created by the cartridge, but
rather by the energy of the recoiling barrel
and action parts.

129
 Figure 1: The feeding step of a tubular magazine-fed recoil-operated action.

INERTIA-OPERATED, LONG feeding sequence and will have different parts

to diagnose.
RECOIL AND SHORT RECOIL
ACTIONS Regardless of feed type, the initial step in the
feeding process of recoil-operated firearms is the
There are three basic recoil-operated designs: same. With a fully loaded magazine, an empty
long and short recoil and inertia-operated. One chamber and a closed breech, the operator ma-
thing that all three action types share is the nipulates the bolt/charging handle or slide. As
fact that the barrel will move with the action the operator drives the bolt/charging handle/
to some degree. The movement of the barrel is slide to the rear of the action, it will begin to
what drives the remainder of the action. You compress the action/recoil spring.
will need to have a thorough understanding of With tubular magazine-fed recoil-operated ac-
the function of the recoil-operated systems and tions, as the action continues rearward, the bolt
the nuances of each action design. Although all will trip the elevator/lifter, which will begin to
recoil-operated firearms function in the same move downward in preparation for feeding. As
basic manner, each individual design will vary the bolt continues rearward, either the bolt or
slightly in its means. elevator/lifter will trip a cartridge release/stop
Recoil Operation Feeding Problems that will allow one round from the magazine
to enter the breech and onto the elevator lifter.
Beginning with the feeding step in the COO, Once the operator has reached the end of the
the first type of malfunction(s) a recoil-operated bolt’s stroke, the action/recoil spring will be
firearm can experience would be failures to feed. fully compressed and ready to drive it forward.
Because of the function of the action, recoil-op-
erated firearms are always magazine-fed, with With the action/recoil spring fully compressed,
the exception of the Browning M2, which is the operator releases the bolt/charging handle,
belt-fed. Depending on the specific model, the allowing the action to move forward under
firearm may be fed by a fixed (tubular) maga- spring force. The action/recoil spring will drive
zine or by a fixed or detachable box magazine. the bolt forward. As the bolt moves forward, it
Each specific feed type will feature a different will trip the elevator/lifter and force it upward,

130
bringing the cartridge into alignment with the release the bolt, which will be driven forward by
bolt. As the bolt continues forward, it will begin the action/recoil spring. The bolt will strip the
to push the cartridge from the elevator/lifter and round from the elevator/lifter and drive it into
drive it into the chamber. The bolt will continue the chamber.
forward until it has contacted the barrel, driving With box magazine-fed (fixed and detachable)
it forward and locking the round in the chamber. recoil-operated actions, as the action continues
With long recoil actions, the feeding step will rearward, the bolt/slide will pass over the top
vary depending on if the round is being fed cartridge in the magazine (pushing it down-
during loading or discharge. When loading the ward slightly) and continue rearward until
first round, the loading step will be similar to it has reached the end of its rearward stroke.
other tubular magazine-fed actions when the Once the bolt/slide has reached the end of its
action is cycling. After the first round is fired rearward travel, the action/recoil spring will be
and the action cycles to the rear, the bolt will fully compressed and ready to drive the action
remain trapped at the rear of the action with forward again.
the empty case while the barrel begins to travel With the action/recoil spring fully compressed,
forward. As the barrel travels forward, an ejec- the operator releases the bolt/charging handle/
tor assembly, which is affixed to the barrel, will slide, allowing the action to move forward under
kick the case from the breech. When the bar- spring force. As the bolt/slide moves forward, a
rel reaches its forward-most position, it will trip lug (typically the cocking lug) on the bottom of
the cartridge release and elevator lifter, which the bolt/slide will contact the head of the car-
will rise into the path of the bolt. Also, when the tridge case and begin to drive it from the maga-
barrel reaches its forward-most position, it will zine. The bolt will continue forward, driving the

Figure 2: The feeding step of a long recoil action firearm.

131
 it may lead to a failure to feed. This includes
the magazine (tubular or box) assembly, eleva-
tor/lifter (tubular magazine firearms only), the
bolt/slide or the action/recoil spring assembly.
If the magazine assembly is broken, damaged,
or worn, it may allow too many cartridges into
the breech at once, or may fail to even feed a
single round. If the elevator/lifter is broken,
damaged, or worn, it may fail to raise the round
into the path of the bolt. If the lug on the bolt/
slide is broken, damaged, or worn, it may fail to
drive the round from the magazine or may cause
misalignment of the round as it moves toward
Figure 3: The feeding step of a box magazine-fed recoil- the chamber. If the action/recoil spring assem-
operated action. bly is broken, damaged, or worn, it may fail to
drive the bolt/slide with enough force to fully
chamber the cartridge. Two less likely (but still
possible) causes of a failure to feed would be a
round from the magazine until it has entered
roughly machined or undersized chamber or ex-
the chamber. The bolt/slide will continue driv-
cessive dirt and debris.
ing the cartridge forward until it has contacted
the barrel, driving the barrel and the action for- Repairing failure to feed malfunctions with
ward until the breech locks. recoil-operated firearms is as simple as replac-
ing the broken, damaged, or worn parts. This
Regardless of the feed device type, once the
includes the magazine assembly (body, spring
bolt/slide has locked up with the barrel, the
and follower), elevator/lifter (tubular magazine
round has been fully fed into the chamber. If
firearms only), bolt/slide, action/recoil spring
any one of the parts that controls the feed-
and chamber. If you must replace the bolt/slide,
ing step becomes broken, damaged, or worn,

Figure 4: Long recoil action locking.

132
you will need to perform a headspace check. If bolt, which will pivot upward into a recess in the
the issue is caused by a short or rough cham- barrel’s extension. The locking block’s engage-
ber, you will need to polish or recut the chamber ment with the barrel extension will lock the bolt
to SAAMI specs. If the chamber is excessively against the barrel.
dirty, you will need to thoroughly clean and With short recoil actions, as the slide moves for-
lightly lubricate the chamber. Once you have re- ward under action/recoil spring force, the barrel
placed parts, you will need to perform a function will be retracted (backward) from its locked po-
and safety check, followed by a test fire. sition. Depending on the specific design of the
Recoil Operation Locking Problems action, the barrel may be tilted, rotated, or inline
from its locked position. As the slide continues
The next type of malfunction you may experi- forward, it will strip a round from the magazine
ence with recoil-operated firearms would be a and drive it into the chamber. When the slide
failure to lock. Every recoil-operated firearm contacts the barrel (driving the round com-
utilizes a true locking breech design, but the pletely in the chamber), it will begin to drive
locking step will vary with each specific action. the barrel forward. As the slide and barrel move
We will discuss the locking step with the three forward together, the barrel will begin to move
major recoil action types (long, short, and iner- into its locked position. Depending on the spe-
tia) and several specific designs. cific design of the action, the barrel may pivot
With long recoil actions, as the bolt is travel- (muzzle down), rotate, or simply move forward
ing forward under action/recoil spring force, the into its locked position. When the barrel has
barrel will already be in its forward-most posi- reached the end of its forward stroke and the
tion. The bolt will strip the round from the el- locking lugs on the barrel (or locking block) and
evator/lifter and drive it into the chamber. The slide are fully engaged, the breech is fully locked
bolt will bottom out against the barrel, tripping and ready for discharge.
the locking block located in the center of the

Figure 5: Short recoil action locking.

133
INERTIA, LONG AND lug on the locking block or the recess of the bar-
rel extension is worn, it may allow the breech to
SHORT RECOIL ACTIONS
unlock prematurely. With short recoil actions, if
With inertia-operated actions, as the bolt the slide, barrel, or (depending on model) lock-
moves forward under action/recoil spring force, ing block, link, barrel pin or barrel bushing is
the barrel will be retracted (backward) from its broken or damaged, it may not allow the breech
locked position. The bolt will strip the round to fully lock. If the locking lugs on the barrel
from the elevator/lifter and drive it into the or slide are worn, they may allow the breech to
chamber. The bolt will bottom out against the unlock prematurely. With inertia-operated ac-
barrel while the bolt carrier continues forward. tions, if the bolt, carrier, cam pin, inertia spring
A slot in the carrier will guide a cam pin located (located between the bolt and carrier), or barrel
in the bolt to force the bolt to rotate as the car- extension is broken or damaged, it may not al-
rier continues forward. When the bolt begins to low the breech to fully lock. If the locking lugs
rotate, the lugs of the bolt will engage lugs on on the bolt and barrel extension are worn, they
the barrel extension. The carrier will continue may allow the breech to unlock prematurely.
forward and continue to rotate the bolt until it The action/recoil spring may also cause lock-
bottoms out against the barrel. Once the carrier ing malfunctions. If the spring is broken, dam-
has bottomed out against the bolt, the locking aged, or worn, it may not drive the action hard
lugs will be fully engaged and the breech will be enough to lock the breech completely. Recoil-
fully locked. operated actions are also susceptible to lock-
If any part or assembly that controls locking is ing malfunctions caused by excessive dirt and
broken, damaged, or worn, the firearm may fail debris. Excessive friction will slow the action
to completely lock. With long recoil actions, if enough to prevent the breech from fully lock-
the bolt, locking block, or barrel extension is ing. A short or rough chamber can also lead to
broken or damaged, the locking lugs may fail locking malfunctions.
to engage or may not engage completely. If the

Figure 6: Inertia-operated action locking.

134
 Figure 7: Recoil-operated action cocking.

Repairing failure to lock malfunctions with they pull the charging handle/slide to the rear
recoil-operated firearms is as simple as replac- of the action, an integral cocking lug on the un-
ing the broken, damaged, or worn parts. This derside of the bolt/slide will contact the strik-
includes the bolt/slide, barrel/extension, lock- ing face of the hammer and begin to drive it
ing block, link, bushing or action/recoil spring. back and downward into the cocked position.
If the action and chamber are excessively dirty, Simultaneously, if the operator is still holding
you will need to thoroughly clean and lightly lu- the trigger, the bolt slide will trip the disconnec-
bricate the action and chamber. If the chamber tor, allowing it to trap the hammer. If the op-
is rough or undersized, you will need to polish erator has released the trigger, the hammer will
or recut the chamber. be trapped by the sear or trigger, fully cocked
and ready to fire. The bolt/slide will continue
Recoil Operation Cocking Problems rearward until it reaches the end of its rearward
Continuing through the COO, the next type of stroke and slams forward under action/recoil
malfunction you may encounter would be a fail- spring force.
ure to cock. The cocking step of a recoil-oper- With striker-fired models, when the operator
ated firearm occurs automatically when the ac- loads the firearm, as the action moves back-
tion cycles after a cartridge has been discharged. ward, the bolt/slide will carry the striker with
The cocking step also occurs when the operator it. Simultaneously, if the operator is still holding
charges the firearm, loading the first cartridge the trigger, the bolt/slide will trip the discon-
into the empty chamber. With recoil-operated nector, allowing the sear to move into position
actions, the cocking step may occur with either a to trap the striker. If the operator has released
hammer or striker. The addition of a part known the trigger, the sear will already be in position,
as the disconnector will also introduce another ready to trap the striker. The bolt/slide will con-
factor when diagnosing issues. tinue rearward until it reaches the end of its
With hammer-fired models, when the opera- rearward stroke and slams forward under ac-
tor loads the firearm in preparation for firing, as tion/recoil spring force. As the bolt/slide travels

135
forward, the striker will be trapped by the sear, Once you have ruled out ammunition and op-
fully cocked and ready to fire. erator error as possible causes for malfunction,
When the operator fires the round, the energy you can focus on the remainder of the action.
created during discharge will drive the bolt/slide The most likely cause of a failure to cock mal-
rearward once more, cocking the hammer/strik- function would be damage or wear to the FCG
er. Each time a round is fired, the action will parts, including the hammer/striker, hammer
cycle and cock the hammer/striker. This cycle strut, trigger, sear, disconnector and respective
will continue until the magazine is empty. springs. If the sear surfaces are worn or damaged,
the hammer/striker may only cock temporarily
If any part or assembly that controls cocking before prematurely falling. If the hammer strut
becomes broken, damaged, or worn, it may lead or hammer or striker spring are damaged or bro-
to a failure to cock. Because of the design of ken, the hammer/striker may fail to cock at all.
the recoil-operated action, ammunition and the
operator can both contribute to cocking mal- A less likely but still possible cause of a failure
functions in the form of short-stroking. Short- to cock would be the action/recoil spring. If the
stroking occurs with blowback actions when action/recoil spring is broken or damaged, it
the cartridge fails to produce enough energy to may not allow the action to travel far enough to
drive the action completely through its stroke. the rear of its travel to fully cock the hammer/
It will also occur when the operator fails to hold striker. Excessive dirt and debris inside the ac-
the firearm with enough force to prevent it from tion can also lead to a failure to cock if the foul-
recoiling excessively, causing the energy used to ing produces enough friction to slow the cycling
cycle the action to dissipate. action. A dirty or roughly machined chamber
can also create enough friction to slow the ac-
tion and cause a failure to cock.

Figure 8: Recoil operated action FCG parts.

136
 Figure 9: Recoil-operated action hammer and striker assemblies.

Repairing failure to cock malfunctions is as sim- contact points. Perform a function and safety
ple as replacing broken, damaged, or worn FCG check before you perform a final test fire to en-
parts. This includes the hammer/striker, strut, sure everything functions correctly.
hammer spring, sear, sear spring, disconnector,
disconnector spring, trigger and trigger springs. Recoil Operation Firing Problems
You may want to replace both sear surfaces (the Moving through the COO, the next type of
sear and hammer/striker) to ensure there are no malfunction that may occur would be a failure
further complications from new parts working to fire. Like other action types, failure to fire
against old parts. In some instances, the sear malfunctions with recoil-operated actions can
surfaces can be dressed (outlined earlier in this be contributed to one assembly: the FCG. The
guide) to try to save hard-to-find parts. Once firing step will vary slightly depending on if the
the parts have been replaced or repaired, thor- system is hammer- or striker-fired.
oughly clean the FCG and lightly lubricate all

137
If the firearm utilizes a hammer assembly, when short side, the firing pin/striker may not be able
the operator presses the trigger and releases the to create a deep enough depression in the prim-
hammer, it will fall and contact the firing pin. The er. If the FCG is excessively dirty, it may create
firing pin will lunge forward, striking the primer enough friction to slow the hammer and firing
and discharging the round. If the firearm utilizes pin or striker enough to create a light strike.
a striker assembly, when the operator presses the Repairing failure to fire malfunctions with
trigger, the sear will release the striker, allowing it recoil-operated firearms is as simple as replac-
to lunge forward and strike the primer. ing the broken, damaged, or worn parts. This
If any part of the FCG becomes broken, dam- includes the hammer/striker, hammer spring,
aged, or worn, the firearm may experience a striker spring, firing pin or other parts of the
failure to fire. The most likely cause of failures FCG that may interfere with the firing step. If
to fire with recoil-operated actions would be a the FCG is excessively dirty, you will need to
broken or damaged firing pin/striker or a worn thoroughly clean and lightly lubricate the parts.
hammer or striker spring. If the firing pin or If the issue is caused by a long chamber, you may
striker is damaged or broken, it may fail to cre- need to replace the barrel or the bolt slide. If you
ate an indentation on the primer or may make do replace the barrel or bolt/slide, you will need
an indentation that is too shallow. If the ham- to perform a headspace check. Once you have
mer or striker spring is worn or broken, it may replaced the parts, you will need to perform a
not drive the hammer/striker quickly enough to function and safety check, followed by a test fire.
strike the primer hard enough.
Recoil Operation Unlocking Problems
A few less likely but still possible causes would
be a long chamber or long headspace or exces- The next type of malfunction that you may ex-
sive dirt and debris inside the FCG. Because perience would be a failure to unlock. The un-
of the allowable tolerances of the chamber, fir- locking step will vary with each specific action
ing pin/striker and cartridge, if the chamber is design but will begin the exact same way. When
on the long side and the ammunition is on the the operator presses the trigger and discharges

Figure 10: Long recoil action unlocking.

138
 Figure 11: Tilting barrel action unlocking.

the cartridge, the energy created during dis- once the bolt has been captured and the locking
charge will force the bullet from the bore and block has released the barrel, a return spring will
force the barrel and action rearward. The barrel drive the barrel (and empty case) forward into
and bolt/slide (being locked together) will move its resting position.
backward under recoil energy. This is where the With short recoil actions, as the slide and bar-
similarities between recoil-operated actions end. rel continue backward under recoil energy, the
With long recoil actions, as the bolt and bar- barrel will be arrested while the slide continues
rel continue backward under recoil energy (still rearward. Depending on the specific design of
locked together), the cocking lug on the bolt the action, the barrel may be arrested by a lock-
will cock the hammer. The bolt and barrel will ing block, pin, or link, which will cause the bar-
continue rearward (locked together) until the rel to tilt, rotate, or remain inline. Tilting barrel
bolt has bottomed out against the rear of the actions use an array of mechanical devices to ac-
receiver. Once the bolt has reached the end of complish locking and unlocking. Some designs
its stroke, three things will happen. An assem- utilize camming lugs of the barrel and locking
bly will capture the bolt, trapping it to the rear block to force the barrel to tilt, which will cause
of the receiver. Another assembly will trip the the locking lugs on the barrel and slide to dis-
locking block, causing it to rotate and release engage. Other designs will use a link and pin to
its lugs from the barrel extension’s recess. And pull the breech end of the muzzle downward to
unlock the action.

139
Designs that rotate will utilize a camming lug With inertia-operated actions, as the barrel and
on the barrel, which will ride in a channel in the bolt travel rearward (still locked together), the
locking block. During unlocking, the barrel will spring between the bolt and carrier will begin
move backward a short distance as the camming to compress. The barrel and bolt will cease their
lug travels the channel in the locking block. The rearward movement as the inertia spring begins
channel will force the barrel to rotate, which will to drive the carrier backward at a higher rate of
free the barrel’s locking lugs from the slide, al- velocity than the barrel/bolt. The channel in the
lowing the slide to continue to move rearward. carrier will force the bolt to rotate as the carrier
Actions that utilize an inline locking system moves backward. Once the lugs of the bolt clear
will use a locking block that surrounds the bar- the lugs on the barrel extension, the bolt and car-
rel and rides along a locking pin. During dis- rier will continue through their rearward stroke.
charge, the barrel, slide, and locking block will Regardless of the specific action type, once the
all move backward together. A cutout in the locking lugs of the barrel/extension and slide/
locking block will force it downward as it moves bolt have disengaged and the barrel and bolt/
across the locking pin. The lugs on the locking slide separate, the action is unlocked. If any part
block will clear the lugs on the slide and allow or assembly that controls unlocking becomes
the slide to continue rearward while the locking broken, damaged, or worn, the firearm may fail
block restrains the barrel. to unlock. This includes the barrel, bolt/slide,
locking block, or any other part that is utilized

Figure 12: Rotating barrel action unlocking.

140
 Figure 13: Inline locking action unlocking.

during the unlocking step. If the locking lugs Recoil Operation Extracting Problems
on either the barrel or the bolt/slide or lock- Continuing through the COO, the next type of
ing block are damaged, they may not be able to malfunction that may occur would be a failure
slide across each other smoothly and can cause to extract. Like other steps in a recoil-operated
the action to fail to unlock. If the action/recoil action’s COO, the extracting step can be affect-
spring is damaged or broken, it may not allow ed by ammunition and improper operator tech-
the action to move far enough to unlock. If the nique. Once ammunition or operator error have
action or chamber is excessively dirty or the been ruled out, you can focus on the firearm.
chamber is rough, it may create enough friction
to slow the action and cause a failure to unlock. With short recoil- and inertia-operated actions,
when the cartridge is discharged, the barrel and
Repairing failure to unlock malfunctions with bolt/slide unlock and the bolt/slide will begin to
recoil-operated firearms is as simple as replac- move backward. As the bolt/slide begins mov-
ing the broken, damaged, or worn parts. This ing backward, the extractor’s claw will grab the
includes the bolt/slide, barrel/extension, locking rim of the empty case. The bolt/slide will con-
block, link, bushing or action/recoil spring. If tinue rearward, dragging the empty case from
the action and chamber are excessively dirty, you the chamber.
will need to thoroughly clean and lightly lubri-
cate the action and chamber. If the chamber is With long recoil actions, after the cartridge is
rough, you will need to polish, thoroughly clean, discharged, the bolt and barrel will travel back-
and lightly oil the chamber. ward until the bolt bottoms out against the rear
of the chamber. As the barrel travels forward

141
 Figure 14: Inertia-operated action unlocking.

under spring force, extractors fixed to the bolt chamber and thoroughly clean and lightly lu-
will hold the empty case to the bolt face. The bricate it. Once you have replaced parts, you will
empty case is extracted from the chamber by the need to perform a function and safety check,
barrel’s forward movement. followed by a test fire.
If any part or assembly that controls extracting Recoil Operation Ejecting Problems
becomes broken, damaged, or worn, the firearm
may experience failure to extract. The most like- The last type of malfunction that may occur
ly cause of extraction malfunctions would be a would be a failure to eject. Like other steps of a
broken, damaged, or worn extractor or extractor recoil-operated action’s COO, the ejection step
spring. If the extractor or spring is damaged or can be affected by ammunition and improper
worn, it may not grab the rim of the case or may operator technique. Once ammunition and op-
slip over the rim prematurely. If the action/re- erator error have been ruled out as the cause of
coil spring is broken or damaged, it may not al- ejection malfunctions, you can focus on the re-
low the action to travel back far enough for the mainder of the firearm.
extractor to remove the case from the chamber. With short recoil- and inertia-operated actions,
If the chamber is dirty or rough or the action after discharge, as the action moves rearward, the
is excessively dirty, it may create so much fric- extractor will pull the empty case into the ejec-
tion that the action does not complete its rear- tor. As the empty case contacts the ejector, it will
ward stroke and fails to extract the case from the begin to rotate around the extractor and out of
chamber. With long recoil actions, if the barrel the ejection port. Most recoil-operated actions
return spring is broken, damaged, or worn, it utilize an ejector that is affixed to the frame.
may cause a failure to extract. With long recoil actions, after discharge, the
Repairing extraction malfunctions with recoil- action will bottom out against the rear of the
operated actions is as simple as replacing the receiver. The barrel will travel forward under re-
broken, damaged, or worn parts. This includes turn spring force while the empty case remains
the extractor, extractor spring, action/recoil with the bolt. An ejector fixed to the barrel ex-
spring or barrel return spring. If the chamber tension will contact the case head as the barrel
is excessively dirty, you will need to thoroughly travels forward. The ejector will cause the case
clean and lightly lubricate it. If the chamber is to rotate around the extractor and out of the
roughly machined, you will need to polish the ejection port.

142
 Figure 15: Short recoil action extracting.

Figure 16: Long recoil action extracting.

If any part or assembly that controls ejecting to drive the barrel forward with enough force
becomes broken, damaged, or worn, the firearm to properly eject the empty case. If the cham-
may experience failure to eject. The most likely ber is rough or excessively dirty, it may create so
cause of a failure to eject would be the ejector much friction that the action cannot eject the
itself. If the ejector is broken, damaged, or worn, case completely.
when the empty case impacts the ejector, it may Repairing ejection malfunctions with recoil-
fail to exit the breech or become jammed in the operated firearms is as simple as replacing the
action. The firearm may also experience erratic broken, damaged or worn parts. This includes
ejection and possibly eject cases directly at the the ejector, action/recoil spring or barrel return
operator. If the action/recoil spring or assembly spring (if applicable). If the chamber is rough,
is damaged, it may not allow the action to travel you will need to polish and thoroughly clean
far enough backward to complete ejection. With it. If the action or chamber is excessively dirty,
long recoil-operated actions, if the barrel return you will need to thoroughly clean and lightly
spring is broken, damaged, or worn, it may fail lubricate it.

143
Figure 17: Short recoil action ejecting.

Figure 18: Long recoil action ejecting.

144
 RECOIL-OPERATED ACTION TROUBLESHOOTING
Malfunction Possible Causes Solution

Failure to Feed 1. Broken, damaged, or worn feed 1. Replace broken, damaged, or

parts, including the magazine as- worn parts or assemblies.
sembly, elevator/lifter, bolt/slide 2. Polish, then clean and oil the
or action/recoil spring. chamber. Recut the chamber
2. A roughly machined or under- to SAAMI specs.
sized chamber.

Failure to Lock 1. Broken, damaged, or worn parts, 1. Replace broken, damaged, or

including the bolt/slide, barrel/ worn parts or assemblies.
extension, locking block, link, 2. Thoroughly clean and lightly
bushing or action/recoil spring. lubricate the action.
2. Excessive dirt and debris in the 3. Polish, then clean and oil the
action or chamber. chamber. Recut the chamber
3. A roughly machined or under- to SAAMI specs.
sized chamber.

Failure to Cock 1. Broken, damaged, or worn, FCG 1. Replace worn or damaged

parts, including the hammer/ parts. Some sear surfaces can
striker, sear, disconnector, trigger be dressed and polished.
or springs. 2. Replace broken, damaged, or
2. Broken, damaged, or worn ac- worn parts.
tion/recoil spring assembly. 3. Thoroughly clean and lightly
3. Excessive dirt and debris in the lubricate the action.
action or chamber. 4. Polish, then clean and lightly
4. Roughly machined chamber. oil the chamber.
Failure to Fire 1. Broken, damaged, or worn FCG 1. Replace broken, damaged, or
parts, including the hammer/fir- worn parts.
ing pin, striker and springs. 2. Replace the barrel or bolt/slide.
2. Long chamber/headspace. 3. Thoroughly clean and lightly
3. Excessive dirt and debris in the lubricate the action.
FCG.
Failure to Unlock 1. Broken, damaged, or worn parts, 1. Replace broken, damaged, or
including the barrel, bolt/slide, worn parts.
locking block, link, pin or action/ 2. Thoroughly clean and lightly
recoil spring. lubricate the action.
2. Excessive dirt and debris in the 3. Polish, then thoroughly clean
action or chamber. and lightly lubricate the cham-
3. Roughly machined chamber. ber.

145
 RECOIL-OPERATED ACTION TROUBLESHOOTING
Malfunction Possible Causes Solution

Failure to Extract 1. Broken, damaged, or worn parts, 1. Replace broken, damaged, or

including the extractor, extrac- worn parts.
tor spring, action/recoil spring or 2. Polish and thoroughly clean
barrel return spring. and lightly lubricate the cham-
2. Excessively rough or dirty cham- ber.
ber.
Failure to Eject 1. Broken, damaged, or worn 1. Replace broken, damaged, or
parts, including the ejector, ac- worn parts.
tion/recoil spring or barrel return 2. Polish and thoroughly clean
spring. and lightly lubricate the cham-
2. Rough or excessively dirty ber.
chamber.

146
 Chapter 7 - Troubleshooting Gas-Operated Actions
TROUBLESHOOTING GAS-OPERATED ACTIONS 149
Short- and Long-Stroke Piston and Direct Impingement Operated Actions 150
Gas-Operated Action Troubleshooting 162
148
 Troubleshooting
Gas-Operated
Actions
Unlike the blowback or recoil-operated actions,
which utilize direct or recoil energy to cycle the
action, the gas-operated action uses high pres-
sure gas tapped from the bore to cycle the ac-
tion. Depending on the specific action design,
the high pressure gas may act directly on the
action (direct impingement) or against a piston
that will (directly or indirectly) drive the ac-
tion. Gas-operated actions are still susceptible
to ammunition-induced malfunctions, but are
less likely to experience malfunctions caused by
operator error.

149
SHORT- AND LONG-STROKE feed type will feature a different feeding se-
PISTON AND DIRECT quence and will have different parts to diagnose.
IMPINGEMENT OPERATED Regardless of feed type, the initial step in the
feeding process of gas-operated firearms is the
ACTIONS
same. With a fully loaded magazine, an empty
There are three basic gas-operated actions: short- chamber, and a closed breech, the operator ma-
and long-stroke piston and direct impingement nipulates the bolt/charging handle (or slide). As
operated. These action types are similar in two the operator drives the bolt/charging handle to
ways: they feature fixed barrels, and when the the rear of the action, it will begin to compress
projectile passes by the gas hole in the barrel, the the action/recoil spring.
gas is forced through the barrel wall and into the With tubular magazine-fed recoil-operated ac-
gas port(s). You will need to have a thorough un- tions, as the action continues rearward, the bolt
derstanding of the function of the gas-operated will trip the elevator/lifter, which will begin to
systems and the nuances of each action design. move downward in preparation for feeding. As
Although all gas-operated firearms function in the bolt continues rearward, either the bolt or
the same basic manner, each individual design elevator/lifter will trip a cartridge release/stop
will vary slightly in the way by which it operates. that will allow one round from the magazine
to enter the breech and onto the elevator lifter.
Gas-Operation Feeding Problems
Once the operator has reached the end of the
Beginning with the feeding step in the COO, bolt’s stroke, the action/recoil spring will be
the first type of malfunction(s) a gas-operat- fully compressed and ready to drive it forward.
ed firearm can experience would be failures
With the action/recoil spring fully compressed,
to feed. Because of the function of the action,
the operator releases the bolt/charging handle,
gas-operated firearms are always magazine-fed.
allowing the action to move forward under
Depending on the specific model, the firearm
spring force. The action/recoil spring will drive
may be fed by a fixed (tubular) magazine or by a
the bolt forward. As the bolt moves forward, it
fixed or detachable box magazine. Each specific

Figure 1: The feeding step of a tubular magazine-fed gas-operated action.

150
 Figure 2: The feeding step of a box magazine-fed gas-operated action.

will trip the elevator/lifter and force it upward, The bolt will continue forward, driving the
bringing the cartridge into alignment with the round from the magazine until it has entered
bolt. As the bolt continues forward, it will begin the chamber. The bolt will continue driving the
to push the cartridge from the elevator/lifter and cartridge forward until it has locked against the
drive it into the chamber. The bolt will continue barrel extension or receiver.
forward until it has contacted the barrel, driving Regardless of the feed device type, once the bolt
it forward and locking the round in the chamber. has locked up with the barrel, the round has
With box magazine-fed (fixed and detachable) been fully fed into the chamber. If any one of
gas-operated actions, as the action continues the parts that controls the feeding step becomes
rearward, the bolt (or slide) will pass over the broken, damaged, or worn, it may lead to a failure
top cartridge in the magazine (pushing it down- to feed. This includes the magazine (tubular or
ward slightly) and continue rearward until it has box) assembly, elevator/lifter (tubular magazine
reached the end of its rearward stroke. Once the firearms only), the bolt/slide, or the action/re-
bolt has reached the end of its rearward travel, coil spring assembly. If the magazine assembly is
the action/recoil spring will be fully compressed broken, damaged or worn, it may allow too many
and ready to drive the action forward again. cartridges into the breech at once, or may fail to
With the action/recoil spring fully compressed, even feed a single round. If the elevator/lifter is
the operator releases the bolt/charging handle, broken, damaged, or worn, it may fail to raise the
allowing the action to move forward under round into the path of the bolt. If the lug on the
spring force. As the bolt moves forward, a lug bolt/slide is broken, damaged, or worn, it may
(typically the cocking lug) on the bottom of fail to drive the round from the magazine or may
the bolt will contact the head of the cartridge cause misalignment of the round as it moves
case and begin to drive it from the magazine. toward the chamber. If the action/recoil spring

151
 Figure 3: Rotating bolt gas-operated action locking.

assembly is broken, damaged, or worn, it may issue is caused by a short or rough chamber,
fail to drive the bolt/slide with enough force to you will need to polish or recut the chamber
fully chamber the cartridge. Two less likely (but to SAAMI specs. If the chamber is excessive-
still possible) causes of a failure to feed would be ly dirty, you will need to thoroughly clean and
a roughly machined or undersized chamber or lightly lubricate the chamber. Once you have re-
excessive dirt and debris. placed parts, you will need to perform a function
Repairing failure to feed malfunctions with gas- and safety check, followed by a test fire.
operated firearms is as simple as replacing the Gas-Operation Locking Problems
broken, damaged, or worn parts. This includes
the magazine assembly (body, spring and fol- The next type of malfunction you may experi-
lower), elevator/lifter (tubular magazine fire- ence with gas-operated firearms would be a fail-
arms only), bolt/slide, action/recoil spring and ure to lock. Every gas-operated firearm utilizes
chamber. If you must replace the bolt/slide, you a true locking breech design, but the locking
will need to perform a headspace check. If the step will vary with each specific action. We will

152
 Figure 4: Falling/tilting breechblock gas-operated action locking.

discuss the locking step of the two major gas- The slot will force the bolt to rotate (in place),
operated actions types: rotating bolt and falling/ which will cause the bolt lugs to align with the
tilting breechblock. As the action is cycling, or locking lugs on the barrel extension. Once the
after the operator has released the bolt/charg- bolt carrier has bottomed out against the breech
ing handle and the bolt has stripped the round face of the barrel and the bolt lugs are in align-
from the magazine/elevator, the bolt will drive ment with the lugs on the barrel extension, the
the round into the chamber. This is where the breech is fully locked.
similarities between the action types end. With falling/tilting breechblock actions, as the
With rotating bolt actions, as the bolt drives breechblock drives the round into the chamber,
the round into the chamber, it will bottom out right before the breechblock bottoms out against
against the fully seated round. The bolt car- the round in the chamber, it will drop into a re-
rier will continue forward (under action/recoil cess in the receiver. The lugs on the breechblock
spring force), forcing a camming pin located in will align with locking lugs on the receiver, lock-
the bolt to follow a cutout slot in the carrier. ing the cartridge in the chamber but not the

153
breech. The breechblock carrier will continue Repairing failure to lock malfunctions with gas-
forward until it bottoms out against the breech operated firearms is as simple as replacing the
face of the barrel, covering the breechblock and broken, damaged, or worn parts. This includes
locking the breech. the bolt/slide, barrel/extension, locking block,
If any part or assembly that controls locking link, bushing or action/recoil spring. If the ac-
is broken, damaged, or worn, the firearm may tion and chamber are excessively dirty, you will
fail to completely lock. This includes the bolt/ need to thoroughly clean and lightly lubricate
breechblock, carrier, receiver, cam pin or barrel the action and chamber. If the chamber is rough
extension. If the locking lugs on the barrel ex- or undersized, you will need to polish or recut
tension/receiver or bolt/breechblock are worn, it the chamber.
may allow the breech to unlock prematurely. If Gas-Operation Cocking Problems
the bolt/breechblock, carrier, cam pin, receiver
or barrel extension is broken or damaged, it may Continuing through the COO, the next type of
not allow the breech to fully lock. malfunction you may encounter would be a fail-
ure to cock. The cocking step of a gas-operated
The action/recoil spring may also cause lock- firearm occurs automatically when the action
ing malfunctions. If the spring is broken, dam- cycles after a cartridge has been discharged.
aged or worn, it may not drive the action hard The cocking step also occurs when the operator
enough to lock the breech completely. Gas- charges the firearm, loading the first cartridge
operated actions are also susceptible to lock- into the empty chamber. With gas-operated ac-
ing malfunctions caused by excessive dirt and tions, the cocking step may occur with either a
debris. Excessive friction will slow the action hammer or striker. The addition of a part known
enough to prevent the breech from fully lock- as the disconnector will also introduce another
ing. A short or rough chamber can also lead to factor when diagnosing issues.
locking malfunctions.

Figure 5: Gas-operated action cocking.

154
With hammer-fired models, when the operator recoiling excessively, causing the energy used to
loads the firearm in preparation for firing, as he/ cycle the action to dissipate.
she pulls the charging handle to the rear of the Once you have ruled out ammunition and op-
action, an integral cocking lug on the underside erator error as possible causes for malfunction,
of the bolt will contact the striking face of the you can focus on the remainder of the action.
hammer and begin to drive it back and down- The most likely cause for a failure to cock mal-
ward into the cocked position. Simultaneously, if function would be damage or wear to the FCG
the operator is still holding the trigger, the bolt parts, including the hammer/striker, hammer
will trip the disconnector, allowing it to trap the strut, trigger, sear, disconnector, and respective
hammer. If the operator has released the trig- springs. If the sear surfaces are worn or damaged,
ger, the hammer will be trapped by the sear or the hammer/striker may only cock temporarily
trigger, fully cocked and ready to fire. The bolt before prematurely falling. If the hammer strut
will continue rearward until it reaches the end or hammer or striker spring is damaged or bro-
of its rearward stroke and slams forward under ken, the hammer/striker may fail to cock at all.
action/recoil spring force.
A less likely but still possible cause of a failure
With striker-fired models, when the operator to cock would be the action/recoil spring. If the
loads the firearm, as the action moves back- action/recoil spring is broken or damaged, it
ward, the bolt will carry the striker with it. may not allow the action to travel far enough to
Simultaneously, if the operator is still holding the rear of its travel to fully cock the hammer/
the trigger, the bolt will trip the disconnector, striker. Excessive dirt and debris inside the ac-
allowing the sear to move into position to trap tion can also lead to a failure to cock if the foul-
the striker. If the operator has released the trig- ing produces enough friction to slow the cycling
ger, the sear will already be in position, ready to action. A dirty or roughly machined chamber
trap the striker. The bolt will continue rearward can also create enough friction to slow the ac-
until it reaches the end of its rearward stroke tion and cause a failure to cock.
and slams forward under action/recoil spring
force. As the bolt travels forward, the striker will Repairing failure to cock malfunctions is as sim-
be trapped by the sear, fully cocked and ready ple as replacing broken, damaged, or worn FCG
to fire. parts. This includes the hammer/striker, strut,
hammer spring, sear, sear spring, disconnector,
When the operator fires the round, the energy disconnector spring, trigger and trigger springs.
created during discharge will drive the bolt rear- You may want to replace both sear surfaces (the
ward once more, cocking the hammer/striker. sear and hammer/striker) to ensure there are no
Each time a round is fired, the action will cycle further complications from new parts working
and cock the hammer/striker. This cycle will against old parts. In some instances, the sear
continue until the magazine is empty. surfaces can be dressed (outlined earlier in this
If any part or assembly that controls cocking guide) to try to save hard-to-find parts. Once
becomes broken, damaged, or worn, it may lead the parts have been replaced or repaired, thor-
to a failure to cock. Because of the design of oughly clean the FCG and lightly lubricate all
the gas-operated action, ammunition and the contact points. Perform a function and safety
operator can both contribute to cocking mal- check before you perform a final test fire to en-
functions in the form of short-stroking. Short- sure everything functions correctly.
stroking occurs with gas-operated actions when
the cartridge fails to produce enough energy to Gas-Operation Firing Problems
drive the action completely through its stroke. Moving through the COO, the next type of
It will also occur when the operator fails to hold malfunction that may occur would be a failure
the firearm with enough force to prevent it from to fire. Like other action types, failure to fire

155
 Figure 6: Gas-operated action FCG.

malfunctions with gas-operated actions can be A few less likely but still possible causes would
contributed to one assembly: the FCG. The fir- be a long chamber or long headspace or exces-
ing step will vary slightly depending on if the sive dirt and debris inside the FCG. Because
system is hammer- or striker-fired. of the allowable tolerances of the chamber, fir-
If the firearm utilizes a hammer assembly, when ing pin/striker and cartridge, if the chamber is
the operator presses the trigger and releases the on the long side and the ammunition is on the
hammer, it will fall and contact the firing pin. short side, the firing pin/striker may not be able
The firing pin will lunge forward, striking the to create a deep enough depression in the prim-
primer and discharging the round. If the fire- er. If the FCG is excessively dirty, it may create
arm utilizes a striker assembly, when the opera- enough friction to slow the hammer and firing
tor presses the trigger, the sear will release the pin or striker enough to create a light strike.
striker, allowing it to lunge forward and strike Repairing failure to fire malfunctions with gas-
the primer. operated firearms is as simple as replacing the
If any part of the FCG becomes broken, dam- broken, damaged, or worn parts. This includes
aged, or worn, the firearm may experience a fail- the hammer/striker, hammer spring, striker
ure to fire. The most likely causes for failures spring, firing pin or other parts of the FCG that
to fire with gas-operated actions would be a may interfere with the firing step. If the FCG
broken or damaged firing pin/striker or a worn is excessively dirty, you will need to thoroughly
hammer or striker spring. If the firing pin or clean and lightly lubricate the parts. If the issue
striker is damaged or broken, it may fail to cre- is caused by a long chamber, you may need to
ate an indentation on the primer or may make replace the barrel or the bolt slide. If you do re-
an indentation that is too shallow. If the ham- place the barrel or bolt, you will need to perform
mer or striker spring is worn or broken, it may a headspace check. Once you have replaced the
not drive the hammer/striker quickly enough to parts, you will need to perform a function and
strike the primer hard enough. safety check, followed by a test fire.

156
Gas-Operation Unlocking Problems With short-stroke piston actions, the tapped
The next type of malfunction that you may gas from the gas port is directed into a gas tube,
experience would be a failure to unlock. The which houses the piston. The high pressure gas
unlocking step will vary with each specific ac- will begin to push the piston backward. Once
tion design, but will begin the exact same way. the piston begins to move, one of two things
When the operator presses the trigger and dis- will happen, depending on the specific design:
charges the cartridge, the pressure created dur- either the piston will act directly against the
ing discharge will force the bullet from the bore. bolt/carrier or against an operating rod that will
Some of this high pressure gas will be diverted act against the bolt/breechblock carrier. The
through a small hole in the barrel called the gas piston (and operating rod) will only move a
port. A part known as the gas block, which rests short distance before stopping, while the carrier
on the barrel and encompasses the gas port, will continues rearward.
direct the gas from the gas port toward the ac- If the system utilizes a breechblock, an angled
tion. This is where the similarities between the lug on the carrier will hook a similar lug on
gas-operated actions end.

Figure 7: Falling/tilting breechblock and rotating bolt short-stroke piston action unlocking.

157
 Figure 8: Rotating bolt long-stroke piston action unlocking.

Figure 9: Rotating bolt gas impingement action unlocking.

the breechblock and force the breechblock to directly to the carrier) backward. As the carrier
rise from the slot in the receiver. As the carrier (and piston) moves backward, the slot in the
continues rearward, it will completely lift the carrier will force the camming pin (or lug) to
breechblock from the slot in the receiver and turn the bolt. Once the bolt’s lugs have cleared
continue rearward to cycle the action. If the the lugs on the barrel extension (or trunnion),
system utilizes a rotating bolt, the slot in the the bolt, carrier, and piston will continue back-
carrier will begin to force the camming pin to ward through their stroke.
start rotating the bolt. As the carrier continues With direct impingement actions, the tapped
rearward, the cam pin will force the bolt’s lugs gas from the gas port is directed into a gas tube,
to clear the lugs on the barrel extension and al- which will direct it from the gas block directly
low the bolt and carrier to travel rearward and to the bolt carrier. The gas tube directs the high
continue through the action’s cycle. pressure gas into a part called the gas key, which
With long-stroke piston actions, the tapped gas transfers the gas into a chamber between the
from the gas port is directed into a gas tube, bolt and carrier. This high pressure gas will force
which houses the piston. The high pressure gas the carrier backward, which will force the bolt to
will begin to push the piston (which is attached begin to rotate. Once the bolt’s lugs have cleared

158
the lugs of the barrel extension, the carrier will the broken, damaged, or worn parts. This in-
carry the bolt rearward through its stroke. cludes the bolt/breechblock, barrel/extension,
If any part or assembly that controls unlocking carrier, gas block, gas tube, piston, operating
becomes broken, damaged, or worn, the fire- rod or action/recoil spring. If the gas port is
arm may fail to unlock. This includes the bolt/ filled with excessive fouling, you will need to
breechblock, barrel, receiver, gas block, gas tube, thoroughly clean the port and possibly re-drill
piston/operating rod, or recoil spring. If the lugs the hole. If the action and chamber are exces-
on the bolt/breechblock or barrel extension/re- sively dirty, you will need to thoroughly clean
ceiver/trunnion become broken or worn, it may and lightly lubricate the action and chamber. If
allow the breech to unlock prematurely. If the the chamber is rough, you will need to polish,
lugs are damaged, they may not allow the breech thoroughly clean, and lightly oil the chamber. If
to unlock at all. If the gas block, gas tube, piston you must replace the bolt or slide, you will need
or operating rod is broken or damaged, it may to perform a headspace check.
fail to drive the carrier backward with enough Gas-Operation Extracting Problems
force to unlock the action. If the gas port on the
barrel is clogged with excessive copper and car- Continuing through the COO, the next type of
bon fouling, it may not allow enough gas pres- malfunction that may occur would be a failure
sure to pass through to completely unlock the to extract. The extraction step of a gas-operated
action. If the recoil spring is broken or damaged, action is susceptible to an ammunition-induced
it may not allow the carrier to move back far malfunction as well as some (extreme) opera-
enough to unlock the breech. If the action and tor-induced ones, in the form of short-strok-
chamber is excessively dirty or if the chamber is ing. Once ammunition and operator error have
rough, it may create enough friction to slow it been ruled out, you can focus on the remainder
and prevent unlocking. of the action.

Repairing failure to unlock malfunctions with When the cartridge is discharged, high pressure
gas-operated firearms is as simple as replacing gas begins to push against the piston or carri-
er, forcing the bolt/breechblock to unlock. The

Figure 10: Gas-operated action extracting.

159
 not allow the action to travel back far enough
for the extractor to remove the case from the
chamber. If the chamber is dirty or rough or
the action is excessively dirty, it may create so
much friction that the action does not complete
its rearward stroke and fails to extract the case
from the chamber. If any part of the gas system
is broken or damaged, it may not be able to drive
the action back far enough for extraction.
Repairing extraction malfunctions with gas-op-
erated actions is as simple as replacing the bro-
ken, damaged, or worn parts. This includes the
extractor, extractor spring, gas system or action/
recoil spring. If the chamber is excessively dirty,
you will need to thoroughly clean and lightly lu-
bricate it. If the chamber is roughly machined,
you will need to polish the chamber and thor-
oughly clean and lightly lubricate it. Once you
have replaced parts, you will need to perform a
function and safety check, followed by a test fire.

Figure 11: Fixed and dynamic gas-operated firearm ejectors. Gas-Operation Ejecting Problems
The last type of malfunction that may occur
would be a failure to eject. Ejection malfunc-
tions can vary with gas-operated firearms be-
cause they employ two different ejector types:
fixed and dynamic. Fixed ejectors are attached
extractor’s claw will grab the rim of the empty to the receiver of the firearm. As the action cy-
case as the bolt begins to move backward. As cles and the bolt/breechblock moves to the rear,
the bolt continues through its rearward stroke, the extractor will pull the case into the ejector
the extractor will drag the empty case from the and cause it to deflect away from the ejector and
chamber. out of the ejection port. Much of the reliabil-
If any part or assembly that controls extracting ity of this type of ejection is dependent on the
becomes broken, damaged, or worn, the firearm shape and location of the ejector and the force
may experience failure to extract. The most like- of the action cycling.
ly cause for extraction malfunctions would be a Dynamic ejectors are spring-driven and live in
broken, damaged, or worn extractor or extrac- the bolt face. The ejector places constant force
tor spring. If the extractor or spring is damaged against the head cartridge case as the extractor
or worn, it may not grab the rim of the case or holds the case to the bolt face and the action
may slip over the rim prematurely. If the ac- is cycling to the rear. Once the case has been
tion/recoil spring is broken or damaged, it may fully extracted from the chamber, the ejector

160
will immediately try to throw the case from the the breech. The firearm may also experience er-
ejection port. The reliability of dynamic ejectors ratic ejection and possibly eject cases directly at
is less dependent on inside forces (the energy of the operator. If the recoil spring or assembly is
the action cycling) and in turn, provides more damaged, it may not allow the action to travel
consistent ejection. far enough backward to complete ejection. If
If any part or assembly that controls ejecting the chamber is rough or excessively dirty, it may
becomes broken, damaged, or worn, the firearm create so much friction that the action cannot
may experience failures to eject. The most likely eject the case completely.
cause for a failure to eject would be the ejector Repairing ejection malfunctions with gas-oper-
itself. With fixed ejectors, if the ejector is bro- ated firearms is as simple as replacing the broken,
ken, damaged, or worn, when the empty case damaged, or worn parts. This includes the ejector,
impacts the ejector, it may fail to exit the breech spring, or recoil spring. If the chamber is rough,
or become jammed in the action. With dynamic you will need to polish and thoroughly clean it. If
ejectors, if the ejector or spring is damaged or the action or chamber is excessively dirty, you will
broken, it may fail to drive the empty case from need to thoroughly clean and lightly lubricate it.

161
 GAS-OPERATED ACTION TROUBLESHOOTING
Malfunction Possible Causes Solution

Failure to Feed 1. Broken, damaged, or worn feed 1. Replace broken, damaged or

parts, including the magazine as- worn parts or assemblies.
sembly, elevator/lifter, bolt/slide 2. Polish, then clean and oil the
or recoil spring. chamber. Recut the chamber
2. A roughly machined or under- to SAAMI specs.
sized chamber.

Failure to Lock 1. Broken, damaged, or worn parts, 1. Replace broken, damaged, or

including the bolt, barrel exten- worn parts or assemblies.
sion, breechblock, receiver, car- 2. Thoroughly clean and lightly
rier, cam pin or recoil spring. lubricate the action.
2. Excessive dirt and debris in the 3. Polish, then clean and oil the
action or chamber. chamber. Recut the chamber
3. A roughly machined or under- to SAAMI specs.
sized chamber.

Failure to Cock 1. Broken, damaged, or worn FCG 1. Replace worn or damaged

parts, including the hammer/ parts. Some sear surfaces can
striker, sear, disconnector, trigger be dressed and polished.
or springs. 2. Replace broken, damaged, or
2. Broken, damaged, or worn recoil worn parts.
spring assembly. 3. Thoroughly clean and lightly
3. Excessive dirt and debris in the lubricate the action.
action or chamber. 4. Polish, then clean and lightly
4. Roughly machined chamber. oil the chamber.
Failure to Fire 1. Broken, damaged, or worn FCG 1. Replace broken, damaged, or
parts, including the hammer/fir- worn parts.
ing pin, striker and springs. 2. Replace the barrel or bolt/slide.
2. Long chamber/headspace. 3. Thoroughly clean and lightly
3. Excessive dirt and debris in the lubricate the action.
FCG.
Failure to Unlock 1. Broken, damaged, or worn un- 1. Replace broken, damaged, or
locking parts, including the bolt/ worn parts.
breechblock, barrel, receiver, gas 2. Clean out the gas port/re-drill.
block, gas tube, piston/operating
rod, or recoil spring. 3. Thoroughly clean and lightly
lubricate the action.
2. Excessive fouling and carbon
inside the gas port. 4. Polish, then clean and lightly
oil the chamber.
3. Excessive dirt and debris in the
action and chamber.
4. Rough chamber.

162
 GAS-OPERATED ACTION TROUBLESHOOTING
Malfunction Possible Causes Solution

Failure to Extract 1. Broken, damaged, or worn parts, 1. Replace broken, damaged, or

including the extractor, extrac- worn parts.
tor spring, recoil spring or gas 2. Polish and thoroughly clean
system. and lightly lubricate the cham-
2. Excessively rough or dirty cham- ber.
ber.
Failure to Eject 1. Broken, damaged, or worn parts, 1. Replace broken, damaged, or
including the ejector, spring or worn parts.
recoil spring. 2. Polish and thoroughly clean
2. Rough or excessively dirty cham- and lightly lubricate the cham-
ber. ber.

163
NOTES
Glossary of Firearm Malfunctions
NOTES
Accidental Discharge – When a cartridge is bore to help alleviate pressure spikes. If the issue
discharged from a firearm unintentionally. An continues, even after cleaning, then the cham-
accidental discharge may be caused by broken ber may be roughly machined. Smooth and pol-
fire control parts or from dirt or debris jamming ish the chamber, taking care not to change the
these parts. Excessive dirt or debris in the firing chamber’s dimensions.
pin channel of certain firearms may cause a slam With semi-automatic firearms, timing issues
fire. Parts breakage may be accidental, but most are harder to diagnose. Fixing timing issues var-
modern day firearms have additional, redundant ies with different action types, but may include
safeties to prevent accidental firing. A slam fire stiffer or lighter action/recoil springs, manipu-
may be prevented and can be blamed on negli- lation of the flow of gas, or increasing or de-
gence of the operator, because of improper or creasing friction of contact points or weight of
poor firearm maintenance. An accidental dis- reciprocating parts.
charge may also be INCORRECTLY referred
to a negligent discharge.
Correction: An accidental discharge can always Blowback – A condition that occurs where hot,
be prevented by practicing safe firearm han- high pressure gas and burning propellant spew
dling. Treating every firearm as if it were loaded, from the breech of a firearm during discharge.
never pointing at anything you don’t intend to Blowback can be caused by excessive headspace,
destroy, and always keeping your finger off the chamber pressure, very “hot” ammunition (load-
trigger are some measures used to prevent an ed to or beyond SAAMI max pressure), or a
accidental or negligent discharge. Even in the combination of multiple factors. Extra pressure
event of parts breakage, by never pointing the or a larger-than-spec chamber can cause cases
firearm at anything you don’t intent to destroy to expand beyond their capacity and rupture,
you can assure little or no injury to you or any- blowing gas and debris out of the breech toward
one around you. the operator. Also, very dirty chambers, throats,
and bores can create dangerously high pressure
spikes that may lead to blowback.
Bent Case Rim – A sign of either a firearm or Correction: The first indicator of blowback that
ammunition malfunction. A bent case rim is a is the easiest to diagnose is excessive chamber
sign of hard extraction either from a rough or pressure. The fired cases will provide most of
dirty chamber, timing issues or an overcharged the evidence. The most obvious signs are blown,
cartridge. A rough or dirty chamber will create flattened, or pierced primers. Taking measure-
extra friction against the case while the extrac- ments of the fired cases and comparing them to
tor tries to remove it from the chamber. Timing SAAMI specifications can also reveal excessive
issues will cause the breech to unlock prema- case stretch, headspace, or incorrect chamber di-
turely, forcing the extractor to pull against a case mensions. Firearms that feature an ejector that
that is still expanded against the chamber walls. protrudes from the bolt face may see signs of the
An overpressure cartridge will cause the case to case head flowing into the ejector hole. If an un-
expand beyond its normal capacity and stick to fired bullet will pass through the neck of a fired
the chamber walls. case, it is a good indication that the neck of the
Correction: Because a bent case rim may be chamber is not undersized or was cut too tight.
caused by either the firearm or ammunition, the Thoroughly cleaning the chamber and bore of
cause must be identified. Use different brands of the firearm is the easiest and most common fix.
ammunition to see if the problem persists. If the Using a quality copper and lead remover may
firearm is determined to be the cause, you can help to alleviate some of the pressure.
start by thoroughly cleaning the chamber and

167
Headspace can be measured with Go/No-Go
gauges to verify the chamber is within spec. If
the chamber is out of spec, the whole barrel
will need to be replaced. If there is not enough
headspace, the chamber may need to be slightly
reamed. If there is excessive headspace, depend-
ing on model, the barrel, bolt, or both may need
to be replaced (Figure 0.1).

Blown Primer – An ammunition or firearm Figure 0.1/0.2- A few cases with undeniable signs of
malfunction where the primer is forced out over-pressure. These cases were pressurized to the point of
of the primer pocket. A blown primer can be failure, causing dangerous amounts of blowback. Blown
primers, and case head extrusion/separation can lead to
caused by excessive headspace, chamber pres-
more serious issues when the escaping hot gasses begin to
sure, excessive cartridge reloading, and may even erode the breech face and other action parts.
be a timing issue. Timing may cause the bolt to
unlock too soon, forcing the extractor to pull a
pressurized case from the chamber. Regardless
of the cause, the real issue is overpressure in the include stiffer or lighter action/recoil springs,
case/chamber/bore area and must be addressed manipulation of the flow of gas, or increasing or
immediately. decreasing friction of contact points or weight
Correction: If only a few cartridges in a particu- of reciprocating parts (Figure 0.2).
lar batch of ammunition have blown primers, it
may be because they were overcharged. If mul- Bolt Override – A firearm or magazine mal-
tiple cartridges over several brands of ammuni- function found in M16/AR-15-style rifles,
tion are blowing primers, then the firearm is where a cartridge or fired case becomes jammed
likely the cause. Also, if a case has been reloaded in the receiver. The case or cartridge becomes
multiple times, the primer pocket may begin to wedged above the bolt between the charging
open from wear. This may cause primers to fit handle and gas key. A bolt override may be
loosely in the pocket, making them more sus- caused by a failure to eject, or by bent or broken
ceptible to blowing. feed lips on the magazine.
If the firearm is the cause, then the first mea- Correction: The first step in clearing a bolt over-
sure would be to clean the chamber and bore ride malfunction is as follows:
thoroughly with a quality copper and lead re-
mover. Also, using Go/No-Go gauges will let 1. Move the selector lever to the “safe”
you verify that the chamber and headspace are position.
within spec. If it is determined that headspace is 2. Depress the magazine release and drop
the cause, the barrel, bolt, or both may need to the magazine.
be replaced depending on model. 3. Clear any loose rounds in the receiver.
With semi-automatic firearms, timing issues 4. With the charging handle in the closed,
are harder to diagnose. Stretching or deforma- locked position and the muzzle pointed at
tion around the case head where the extractor the ground, use the head of a cartridge or
pulled the case from the chamber or bulges lip of the magazine to push up against the
around where the ejector sits against the case bolt carrier.
are signs of a timing issue. Fixing timing is-
sues varies with different action types, but may 5. Shake the rifle, and use gravity to clear
the obstruction.

168
 Figure 0.3- A bolt override can be a difficult malfunction
to try to clear quickly. The first step in clearing any
malfunction is properly identifying the type of malfunction
(1). Remember that with a bolt override malfunction the
cartridge/case is jammed between the charging handle
and bolt carrier, so trying to manipulate the charging
handle will only make things worse. Work slowly and
keep your fingers clear of the breech because the bolt carrier
is under spring tension and will slam shut when the case
is removed. Initiate the safety and remove the magazine
(2). Use the head of a case to push the carrier to the rear
and shake the rifle to help remove the case (3).

6. Cycle the action to make sure all obstruc- cause comes from a weak or broken magazine
tions have been cleared. spring failing to lift the cartridges fast enough
The rifle is now ready to load and fire. for feeding. A bolt-over-base malfunction may
also be caused by a worn or out-of-spec bolt or
If the problem persists, there may be some- slide, magazine catch, or by a condition known
thing mechanically wrong with the firearm or as short-stroking. A bolt-over-base malfunction
magazine. If only one magazine causes the mal- is a type of failure to feed.
function, the magazine is the issue. If the mal- Correction: To clear a bolt-over-base malfunc-
function occurs with multiple magazines, then tion you must first do the following:
the ejector in the bolt may be the cause. If the
ejector is found to be the cause, then it should 1. Initiate the safety device, if possible.
be replaced (the ejector spring also if possible) 2. Depress the magazine release and drop
(Figure 0.3). the magazine.
3. Lock the bolt or slide open, if possible.
Bolt-Over-Base – A firearm, magazine, or op- 4. Turn, shake, and use gravity to clear the
erator malfunction where the bolt or slide rides obstruction from the breech.
over a round in the magazine, failing to chamber 5. Cycle the action multiple times to make
it, and causing a jam. The most common bolt- sure all obstructions have been cleared.
over-base cause comes from a magazine that is
not fully seated and locked into place. Another The firearm is now ready to load and fire.

169
The first step in avoiding a bolt-over-base mal- can also be attributed to work hardening. A
function is to ensure the magazine is locked se- case head separation can be very dangerous as
curely in the firearm. If one magazine causes the it may let hot, high pressure expanding gas out
same malfunction multiple times, the magazine through the breech.
may be bad. If multiple magazines cause the Correction: Because head separation is found
same malfunction, then the firearm may be the mostly with reloaded cases, using new factory-
issue. A good way to pinpoint the problem is to loaded ammunition will ensure reliable opera-
cycle snap caps through the action and watch tion. Thoroughly examine each case when re-
where the jam occurs. Replace or repair parts loading for discolored rings or hairline cracks
(magazine, springs, follower, magazine catch, near the case head. Use a paperclip to feel for
bolt or slide) as needed (Figure 0.4). thin spots on the inside of the case near the
head. If head separation occurs and the ammu-
Case Head Separation – A cartridge failure nition is not the cause, then there may be an
commonly found with reloaded cases, where issue with the firearm. Excessive headspace and
the brass becomes thin or fatigued near the pressure or timing issues can cause head sepa-
case head. When fired, the head blows off or ration. Also, a roughly machined chamber may
is ripped off by the extractor. Head separation lead to head separation.

Figure 0.4- A bolt-over-base malfunction (1) is typically caused by the operator failing to seat the magazine
properly. To clear a bolt-over-base, initiate the safety and remove the magazine (2). Manipulate the charging
handle (3) and shake the firearm to free the stuck cartridge. This same procedure can be used for any type of
repeating, magazine-fed firearm. The only difference is in the names of the action parts (bolt/charging/operating
handle or slide).

170
Thoroughly cleaning the chamber and bore of
the firearm is the easiest and most common fix.
Using a quality copper and lead remover may
help to alleviate some of the pressure.
Headspace can be measured with Go/No-Go
gauges to verify the chamber is within spec. If
the chamber is out of spec, the whole barrel
will need to be replaced. If there is not enough
headspace, the chamber may need to be slightly
reamed. If there is excessive headspace, depend- Figure 0.5- Reloading a case multiple times or loading
ing on model, the barrel, bolt, or both may need it beyond SAAMI recommended maximum load can
cause case head separation. Multiple loadings can cause
to be replaced.
work hardening in the brass that lead to stress fractures
With semi-automatic firearms, timing issues and eventually complete separation. Loading a cartridge
are harder to diagnose. Stretching or deforma- beyond recommended safe load can cause excessive
tion around the case head where the extractor chamber pressure that can either blow the case head off or
pulled the case from the chamber or bulges cause it to be ripped off by the extractor.
around where the ejector sits against the case
are signs of a timing issue. Fixing timing issues
varies with different action types, but may in-
clude stiffer or lighter action/recoil springs, ma-
Double Feed – A firearm or magazine malfunc-
nipulation of the flow of gas, or increasing or
tion where there is a cartridge being fed into
decreasing friction of contact points or weight
a chamber that already contains a cartridge or
of reciprocating parts.
case. Double feeds can be caused by a fail to ex-
A rough chamber can be lightly polished to al- tract or by bent or broken magazine feed lips
leviate some friction when the extractor pulls allowing more than one round to be released at
against the case head. Care must be taken not a time.
to alter the dimensions of the chamber because
Correction: To clear a double feed you must first
it may lead to more serious issues (Figure 0.5).
do the following:
1. Initiate the safety, if possible.
Cook Off – A condition where a cartridge is dis-
2. Depress the magazine release and remove
charged through thermal ignition. Cook off is
the magazine.
caused by an overheated chamber igniting the
primer or propellant. Cook off is mostly en- 3. Cycle the action and use gravity to help
countered with automatic firearms and extensive clear the cases and cartridges. Once all
rapid firing. cartridges and cases are clear, the firearm
is ready to load and fire.
Correction: If cook off occurs when using a
semi-automatic firearm that employs a closed After experiencing a double feed, try using a
bolt design, cease fire immediately. Remove the different magazine to see if the problem con-
magazine and any remaining cartridges from tinues. If the magazine is the issue, the feed lips
the firearm and lock the breech open. Allow the may be bent or damaged. If the issue persists,
action and chamber to cool before continuing. the extractor, extractor spring, ejector or ejec-
Cook off can be prevented by avoiding excessive tor spring may be worn, bent or broken and
and prolonged rapid firing. need to be replaced.. A roughly machined or
dirty chamber may cause cases to become stuck,

171
leading to a double feed. Cleaning and polish-
ing the chamber may help alleviate any extrac-
tion issues (Figure 0.6).

Dud – A cartridge whose primer or propellant

fails to ignite. A dud must be handled with care
because there is still a slight chance the round
will still ignite, like in the case of a hang fire.
Correction: To clear a dud, the first thing you
must do is wait at least a minimum of 30 sec- Figure 0.7- Even though there was sufficient energy
onds. After 30 seconds, initiate the safety, if pos- striking the primer, the round still failed to ignite.
sible. Remove the dud from the chamber and Improper storage is the most likely cause. The powder,
dispose of it properly (most ranges will have a primer or both may have been exposed to moisture that
bucket for duds) (Figure 0.7). would cause it to deteriorate.

Extruded Case Head/Primer – An ammuni- Correction: Because extrusion can be caused

tion malfunction where pressure causes case/ by either the firearm or ammunition, the cause
primer material to flow into the ejector/firing must be determined. Use different brands and
pin channel. Extrusion is typically caused by an lots of ammunition to see if the issue persists.
overcharged cartridge but may also be caused If the firearm is determined to be the cause,
by excessive fouling in the chamber/bore of the then you should thoroughly clean the cham-
firearm causing pressure spikes. ber and bore of fouling (copper, lead, carbon

Figure 0.6- A double feed malfunction (1) is most

often caused by bent or broken feed lips. To clear
a double feed, initiate the safety and remove the
magazine (2). Manipulate the slide to clear any loose
rounds from the breech. This same procedure can be
used to clear a double feed in any type of repeating,
magazine-fed firearm. The only difference is in the
names of the action parts (bolt/charging/operating
handle or slide).

172
and propellant) buildup. If the problem persists, Fail to Extract – A firearm malfunction where
check the dimensions of the chamber to assure the extractor is unable to remove the spent
it is within spec. A “tight” chamber will cause an case from the chamber. A fail to extract may
increase in pressure that could lead to extrusion. be caused by damage or wear to the extractor,
Replace or repair the barrel if necessary. a weak extractor spring, or by a dirty or rough
chamber. A fail to extract may also be caused
by ammunition, wherein steel cases may be-
Fail to Eject – A firearm malfunction in which come stuck in the chamber because they do not
the ejector fails to expel the spent case from contract as much as brass. Reloaded ammuni-
the breech before the action closes, causing the tion may cause a fail to extract in the case of a
spent case to become stuck. A failure to eject can head separation. A failure to extract may lead
be caused by a bent or damaged ejector or from to a double feed with semi-automatic firearms.
insufficient spring pressure. A failure to eject on Also, if a round has been loaded and unloaded
semi-automatic pistols may also be caused by a multiple times without firing, the case head may
condition known as limp wristing. become worn or chipped, allowing the extractor
Correction: If you experience a failure to eject to slip over and leaving the cartridge behind.
while shooting, you must first do the following: Correction: While shooting, if you experience a
1. Initiate the safety, if possible. failure to extract you must first do the following:

2. Remove the magazine (semi-automatic) 1. Initiate the safety, if possible.

or open/remove the cylinder (revolver). 2. Remove the magazine (semi-automatic).

3. Use gravity to assist you when removing 3. Rack the slide, manipulate the bolt, or
the spent case. Repeatedly manipulate the push the ejector rod (revolvers) several
slide or bolt (semi-automatic or other re- times to try to catch the case rim. If the
peaters) or depress the ejector (revolver). cartridge does not extract and eject, you
will need to remove the round from the
If you are unable to eject the case, or if the prob- muzzle end. This can be very dangerous
lem continues, you may have to replace, repair when removing a live cartridge.
or tune the ejector or ejector spring. With some To remove a fired case, you must first open the
types of semi-automatic actions the erratic ejec- action and secure the bolt/slide/breechblock
tion may be caused by ammunition or timing is- to the rear. Tap the case out from the muzzle
sues. Any inconsistencies from round to round end with a wood or soft metal (brass or alumi-
will cause erratic ejection and could cause a num) rod that is slightly smaller than the bore
malfunction. in diameter.
With pump-, bolt-, and lever-actions the ejec- To remove a live cartridge, you must remember
tion issues may be operator-induced. Failing to to ALWAYS keep the firearm pointed in a safe
fully cycle the firearm’s action the total distance direction. If possible, try to fire the round into
of its travel, or failing to cycle the action hard or an appropriate backstop. If you are unable to
smooth enough, can lead to ejection issues. To discharge the round, you need to open the ac-
correct a failure to eject that is caused by limp tion and secure the bolt/slide/breech to the rear.
wristing, you simply have to lock your wrists Tap the case out from the muzzle end with a
while you are shooting. wood or soft metal (brass or aluminum) rod that
is slightly smaller than the bore in diameter. If

173
you are unable to remove the cartridge, you can rough, you must polish out the machine marks,
try to freeze the action and barrel. The thin- taking care not to alter the dimensions of the
walled brass case will contract more than the chamber (Figure 0.8).
thick-walled steel chamber. Try to tap it out
with a rod once again. If the case remains stuck,
you may need to disassemble the firearm and Fail to Feed – A firearm’s malfunction that oc-
remove the barrel. curs when a cartridge fails to align properly
while entering the chamber, creating a malfunc-
In the case of a head separation, there is no case tion in the form of a jam. A failure to feed can
head to pull or tap against. You can use a brass be caused by the firearm, or by the magazine,
bore brush that is larger in diameter than the in- or ammunition. Most modern semi-automatic
side diameter of the case to try to create enough firearms feature some type of feed ramp either
friction to remove the case. You can also use a on the receiver or integral with the barrel to help
specialized tool known as a broken shell extractor. guide cartridges into the chamber. Sometimes
If you continue to experience extraction issues, these ramps are designed only for a specific bul-
you need to determine if the firearm or ammu- let profile, like a round nose full metal jacket,
nition is the cause. Use various brands and types and will have difficulty feeding bullets with an
of ammunition. If you experience extraction open tip profile like a hollow-point. If magazine
issues with multiple types of ammunition, you feed lips are bent or out of spec, they can fail to
may need to repair, replace or tune the extractor. align the next cartridge properly.
If the issue persists, you should check the cham- Correction: With semi-automatic firearms, most
ber for rough machining that may be causing feeding issues are caused by the magazine it-
excessive friction on the cases. If the chamber is self. Try using different magazines to see if the

Figure 0.8- A failure to extract (1) can lead to other

malfunctions, such as a double feed. To clear a double
feed you need to initiate the safety and remove the
magazine (2). Manipulate the slide until all loose
rounds have cleared the firearm (3). This same
procedure can be used to clear a failure to extract in
any type of repeating, magazine-fed firearm. The
only difference is in the names of the action parts (bolt/
charging/operating handle or slide).

174
 Figure 0.9- A failure to feed (1) can have several
causes. To clear a failure to feed you must initiate the
safety and remove the magazine (2). Manipulate the
slide until all loose rounds are free from the firearm.
This same procedure can be used to clear a failure to feed
in any type of repeating, magazine-fed firearm. The
only difference is in the names of the action parts (bolt/
charging/operating handle or slide).

issue is with the magazines or firearm itself. The Correction: If failures to fire are experienced
same applies to different types of ammunition with different brands and lots of ammunition,
with different tip profiles (round, hollow, flat, or than the issue is with the firearm. Any part of
stepped/truncated). the fire control group could be responsible for
If you are experiencing issues with multiple the issues. Clean and lubricate the firearm, espe-
magazines and types of ammunition, then you cially the fire control parts, to see if the problem
may need to address the feed ramp and throat continues.
area of the barrel. You may need to lightly polish With hammer-fired firearms, you will need to
or reprofile the feed ramp and throat to aid in examine the hammer, hammer spring, firing pin,
the cartridge’s alignment and feeding into the firing pin spring, decocker/safety(s) and transfer
chamber (Figure 0.9). bar (if applicable). Check the hammer and firing
pin for burrs and signs of dragging. Remove all
burrs and smooth or polish scratches and polish
Fail to Fire – A firearm or ammunition malfunc- the contact points of dragging parts. Check the
tion where the cartridge fails to ignite. The failure firing pin tip for chips or breakage. Make sure
may be due to an insufficient amount of energy springs are not sagging or worn. Replace springs
striking the primer, a defective primer, or because as necessary.
of propellant or cartridges that have been ruined
from improper storage. See also Dud. For striker-fired firearms, you will need to ex-
amine the striker, striker spring, sleeve(s) and

175
safety(s). Check the striker and safety(s) for serious problems. Either the barrel, the bolt/
burrs or signs of dragging. Remove burrs and slide/breechblock, or both will need to be re-
smooth and polish scratches and contact points. placed (Figure 1.0).
Check the striker tip for chips or breakage.
Check springs for sagging and wear and replace
if necessary. Hammer Follow – A firearm malfunction that
occurs when the hammer or striker chases the
bolt or slide as it closes and locks the breech.
Flattened Primer – An indication or sign of Hammer follow can result in a light strike or fail
high or excessive pressure or headspace. Some to fire, it can also lead to an accidental discharge
calibers of ammunition will normally flatten (slam fire) in a worst case scenario. Hammer
a primer slightly. If a primer is flattened com- follow may be a result of a faulty disconnector
pletely, it is a sign of overpressure and could lead or bad sear engagement.
to a dangerous situation. Also, because of vari- Correction: A bent or broken disconnector/in-
ances in material of manufacture, some primers terrupter can release the hammer prematurely.
may flatten more than others. Repair or replace the disconnector and replace
Correction: Excessive pressure can be caused by the disconnector spring. If the problem persists,
either the firearm or ammunition. To determine check hammer/sear engagement.
which is the cause, try using different brands of Any alteration of hammer/sear engagement from
ammunition to see if the problem persists. If the angle to shape may cause the hammer to slip and
firearm is determined to be the cause, the first follow the bolt/slide. There are two safe and one
step to try to solve the issue is to thoroughly dangerous hammer/sear engagement profiles.
clean the firearm, especially the chamber and A positive or neutral sear engagement angle
bore. Any buildup of fouling (lead, copper, car- will create a safe but sometimes heavy (positive
bon, propellant) can lead to flattened primers. angle) trigger pull. A negative sear engagement
Excessive headspace can also cause primers to angle will allow the hammer to push or slip off
flatten when the case head slams against the of the sear. If the hammer or sear cannot be re-
bolt/breech face. Headspace can be measured paired, then they must be replaced (Figure 1.1).
with Go/No-Go gauges. If headspace is de-
termined to be the issue, it may lead to more

Figure 1.1- The angle of the sear in relation to the

Figure 1.0- There is a clear difference between the profile hammer/striker’s sear surface and its direction of travel
of the normal (left) primer and the flattened (right) one. will greatly affect how the fire control group performs. The
Even the profile of the crater from the firing pin strike angle can mean the difference between a safe (positive/
shows pressure signs. The damage to the case rim is also neutral) or dangerous (negative) trigger or a heavy
another indicator of pressure causing hard extraction. (positive) or short, light (neutral with bevel) trigger.

176
Hang Fire – An ammunition malfunction
where there is a delay in propellant ignition af-
ter the primer has been struck. The cartridge
may fire a few seconds after the initial strike.
This situation should be treated with caution.
Correction: A hang fire may be confused with
a dud or fail to fire. If you experience what you
think may be a dud/fail to fire, you should keep
the firearm pointed in a safe direction for a min-
imum of 30 seconds. After 30 seconds you can
be assured that ignition is very unlikely.
Figure 1.2- The shallow indentation is a sign of a
light strike. Somewhere in the fire control group there
Light Strike – A firearm malfunction that occurs is a broken part or an excessive amount of friction.
Repairing broken parts or replacing worn springs will
when the firing pin does not have enough energy
solve this issue.
to properly crush the anvil and primer to create
ignition. A light strike may be a result of worn or
damaged firing pin springs or hammer springs, Limp Wristing – While shooting recoil-oper-
or from a condition known as hammer follow. ated firearms, it is a condition that will cause
Correction: Any part of the fire control group a malfunction known as a short stroke. Most
could be responsible for the issues. Clean and commonly found with semi-automatic pistols
lubricate the firearm, especially the fire control when the receiver is allowed to move with the
parts, to see if the problem continues. Check the slide, absorbing energy needed to cycle the ac-
hammer/striker/firing pin springs to assure that tion. Limp wristing is caused when the firearm
it has not begun to sag and still produce suf- is not held securely enough or while shooting
ficient pressure. Replace as needed. Also, check pistols when the wrists are not locked.
the fire control parts for wear or signs of drag- Correction: Limp wristing can be cured with a
ging. Smooth or polish any contact points to al- proper grip. Getting the shooting and support
low for fluid motion (Figure 1.2). hands as high up against the bore axis of the

Figure 1.3- For a semi-automatic pistol to perform reliably, all of the available energy used to cycle the action must be
transmitted to the slide. If the frame is allowed to move, it will absorb cycling energy and cause the slide to reduce its amount
of travel. If the slide is unable to travel the full distance of its stroke, it could fail to extract the spent case, eject the spent case,
cock the hammer/striker, feed a new round or lock the breech.

177
firearm will prevent the muzzle from flipping
excessively. Locking your wrists and gripping
the firearm with enough force so that it does not
slip in your hands will also cure any issues. Also,
the use of isometric tension will aid in securing
the firearm and controlling recoil (Figure 1.3).

Misfire – A failure of a cartridge to ignite after

the primer is struck. A misfire can occur from
wet or chemically deteriorated propellant or
debris in the flash hole. A misfire is a type of
failure to fire. See also Dud. Figure 1.4- Continuously reloading cartridges without
periodically annealing them can lead to work hardening
of the neck and shoulder and eventually fractures and
Neck Split – A type of ammunition malfunc- cracks. Annealing the neck/shoulder area of the case will
tion where the neck area of the case fractures. return some of its ductility and make it safe to reload a
The most likely cause of a neck split comes from few more times.
work hardening. Work hardening occurs in cases
that have been reloaded multiple times. A neck
split may also be the result of dirt or debris in
the chamber. During discharge, chamber pres- Pierced Primer – A primer that has been punc-
sure forces the case against the debris creating tured by a firing pin that is too long or that has a
a pressure point, and cracking. Also known as a sharp face. Excessive wear on the firing pin can
season crack. cause it to protrude further from the firing pin
Correction: A neck split is a case malfunction hole than normal. Piercing can also be caused
most commonly associated with reloading. If by excessive chamber pressure that forces the
you do not reload and experience a case neck primer crater back toward the firing pin, push-
split, you should clean the chamber area of the ing it back and creating a hole. High pressure
barrel. If the problem persists, the chamber may ammunition that is near or beyond SAAMI-
be damaged or out of spec. If the chamber is out recommended maximum load can cause a prim-
of spec or damaged, the barrel will need to be er to become punctured. Pierced primers allow
replaced (Figure 1.4). hot gas to escape and erode the bolt face and the
firing pin hole.

Negligent Discharge – An unexpected dis- Correction: Because a pierced primer could be

charge of a firearm due to carelessness. Usually a result of the ammunition or firearm malfunc-
caused by putting a finger inside of the trigger tioning, you need to diagnose the cause. Use
guard when a round is chambered. A negligent multiple brands of ammunition to see if the
discharge is an operator induced malfunction. problem persists. If you continue to experience
pierced primers with multiple types of ammuni-
Correction: A negligent discharge can be pre- tion, then the firing pin may be damaged. Check
vented by practicing safe firearm handling. Treat the tip of the firing pin for burrs or damage and
every firearm as it were loaded, always point it in measure its protrusion from the bolt/breech
a safe direction, and never point it at anything face. Replace the firing pin/striker as needed.
you are not willing to destroy. Also, keep your
finger away from the trigger, outside of the trig- Excessive chamber pressure may also cause
ger guard, along the frame until your sights are a primer to become pierced. A dirty or heav-
on target and you are ready to shoot. ily fouled (copper, lead, carbon, propellant)

178
 Headspace can be measured with Go/No-Go
gauges to verify the chamber is within spec. If
the chamber is out of spec, the whole barrel
will need to be replaced. If there is not enough
headspace, the chamber may need to be slightly
reamed. If there is excessive headspace, depend-
ing on model, the barrel, bolt, or both may need
to be replaced.
With semi-automatic firearms, timing issues
are harder to diagnose. Stretching or deforma-
tion around the case head where the extractor
Figure 1.5- This primer was pierced by a firing pin pulled the case from the chamber or bulges
with a damaged tip. A combination of the pressure
around where the ejector sits against the case
inside the case and the fractured firing pin tip created
a perforation in the primer cup that could release hot,
are signs of a timing issue. Fixing timing issues
high pressure gases into the breech and possibly back at varies with different action types, but may in-
the operator (blowback). clude stiffer or lighter action/recoil springs, ma-
nipulation of the flow of gas, or increasing or
decreasing friction of contact points or weight
of reciprocating parts.
chamber and bore can create pressure spikes
inside the case. Thoroughly clean the chamber A rough chamber can be lightly polished to al-
and bore to remove any fouling (Figure 1.5). leviate some friction when the extractor pulls
against the case head. Care must be taken not to
Ruptured Case (Separated Case) – A case that’s
alter the dimensions of the chamber because it
been blown apart, usually just ahead of the rim.
may lead to more serious issues.
Normally caused by excessive headspace, pres-
sure or multiple reloads and resizings. A rup-
tured case may also be the result of work hard- Short Stroke – A semi-automatic firearm mal-
ening. See also Case Head Separation. function in which the bolt/breech or slide does
Correction: Because ruptured cases are found not complete the full travel of its cycle. Short-
mostly with reloaded cases, using new factory- stroking may cause a fail to extract/eject, fail to
loaded ammunition will ensure reliable opera- cock the hammer or engage the sear, or failure to
tion. Thoroughly examine each case when re- feed. Short-stroking can be caused by low power
loading for discolored rings or hairline cracks ammunition, debris in the action parts, or hu-
near the case head. Use a paperclip to feel for man error in the form of limp wristing. Also, if
thin spots on the inside of the case near the there is any disruption of the flow of gas in gas-
head. If head separation occurs and the ammu- operated firearms, it may lead to a short stroke.
nition is not the cause, then there may be an Correction: Since a short stroke can be caused by
issue with the firearm. Excessive headspace and either the ammunition, the firearm or the oper-
pressure or timing issues can cause head sepa- ator, you need to determine the cause. Try using
ration. Also, a roughly machined chamber may different brands and lots of ammunition to see
lead to head separation. if the problem persists. If the problem persists,
Thoroughly cleaning the chamber and bore of clean the firearm thoroughly and lubricate any
the firearm is the easiest and most common fix. contact/friction points.
Using a quality copper and lead remover may If the cause is determined to be operator er-
help to alleviate some of the pressure. ror, limp wristing is the most likely cause.
Limp wristing can be cured with a proper grip.

179
Getting the shooting and support hands as firing pin as needed. Check the firing pin re-
high up against the bore axis of the firearm will turn spring (if applicable) for wear or sagging.
prevent the muzzle from flipping excessively. Replace if necessary. Clean the firing pin and
Locking your wrists and gripping the firearm firing pin channel and lubricate if needed.
with enough force so that it does not slip in your
hands will also cure any issues. Also, the use of
isometric tension will aid in securing the fire- Slide/Hammer Bite – An incident where the
arm and controlling recoil. shooter’s hand is so high up on a pistol’s grip
that it interferes with the slide or hammer while
If the problem persists, there may be other is- operating. Slide/hammer bite usually causes in-
sues with the firearm. There may be burrs, jury to the operator and malfunctions to the fire-
scratches or damaged action parts. Remove any arm. With semi-automatic pistols, it may cause
burrs, polish out any rough spots or scratches, short-stroking. With a revolver, you may not be
and repair or replace broken or damaged parts able to cock the hammer or fire double action.
and worn springs.
Correction: Curing slide/hammer bite is as sim-
Gas-operated firearms present another set of ple as adjusting your shooting grip. Move your
issues that can contribute to short-stroking. If hand so that the webbing between your index
there is a buildup of carbon or other obstruc- finger and thumb is clear of the slide/hammer.
tions in the gas system that block gas flow, the There are some models of pistols that can be
firearm will not cycle completely. Any misalign- equipped with extended beavertail to help pre-
ment of the gas port/block/tube will reduce the vent slide/hammer bite.
amount of gas used to cycle the action. Clean
out the gas system and make sure all the ports
are aligned. Also, with gas/piston firearms, the Spitting – Flame, spark, and metal shavings
piston/operating rod may be bent or damaged blown out of the barrel/cylinder gap of a revolv-
and needs to be replaced. er. Depending on the type of ammunition used,
spitting can be a normal occurrence. When us-
ing magnum, +P or +P+ ammunition, it is not
Slam Fire – The unintentional discharge of a uncommon to see flame or spark blown out of
firearm when the breech is closed on a fresh the gap from the increased pressures. When us-
cartridge. A slam fire may occur from a few ing normal loads, any spitting may be a result
scenarios: of a larger-than-acceptable cylinder gap, or a
• a stuck firing pin caused by dirt and debris cylinder whose timing is off. If the cylinder gap
• a broken firing pin return spring that is too large, an excessive amount of hot gas and
fails to overcome the energy of the action burning propellant will spit out. If the cylinder’s
closing timing is off and the chamber is not aligned
• inadequate headspace with the bore upon firing, pieces of the bullet or
jacket may shear off.
• a cartridge with a sensitive or improperly
seated primer Correction: Because spitting is a common oc-
currence with some calibers and brands of am-
Correction: If you experience a slam fire, stop munition, you need to know the difference be-
shooting immediately. Remove the firing pin/ tween normal and irregular or unsafe. You will
striker from the bolt/slide/breech and examine need to measure the cylinder gap with feeler
it for burrs or damage. Replace or repair the gauges. Depending on caliber and model, the

180
gap should be somewhere between .006 in. and to push the bullet out of the side with the least
.010 in. If the gap is larger than .010 in., then amount of travel.
the barrel will have to be set back further in the Using a cleaning rod made of soft metal (brass
frame to close the gap. or aluminum), a small hammer with a hard plas-
Timing a revolver is a bit more challenging. tic face, and some type of lubricant, you should
Depending on model, the hand/paw, ratchet, be able to successfully remove the stuck round.
trigger, hammer, cylinder stop or any other part Lightly lubricate the round and place the clean-
of its fire control group can create timing is- ing rod up against the obstruction. Lightly tap
sues. Examine parts for breakage or wear. Make the rod with the hammer until the obstruction
sure all springs have sufficient pressure. Replace starts to move. Continue to tap the rod until the
parts as needed. When timing is correct, the obstruction is completely removed.
cylinder will lock in place when the hammer is
fully cocked.
Stove Pipe – A type of malfunction mostly
found with semi-automatic pistols. A stove pipe
Squib Load – An ammunition malfunction in occurs when a partially ejected case is caught
which there is an insufficient amount of energy vertically between the slide and barrel. Stove
pushing the bullet through the bore, causing it piping occurs on recoil-operated pistols because
to become stuck. A squib load can be caused by there is an insufficient amount of energy mov-
too small of a propellant charge, failure of the ing the slide, or the receiver is allowed to move
primer to ignite the propellant, or an out-of- with the slide causing a short stroke. Any re-
spec bullet. Squib loads can usually be identi- sistance will negate the slide’s energy and will
fied by their reduced sound and lack of recoil, or affect extraction and ejection. The main cause of
failure to cycle the action of a semi-automatic. stove piping is a condition known as limp wrist-
Failure to recognize a squib load may result in ing, but it could also be caused by a malfunc-
catastrophic failure of the firearm if a second tioning firearm or under-powered ammunition.
round is fired into the obstruction. Squib loads Stove piping may also be referred to as smoke
are often contributed to new or inexperienced stacking.
reloaders and failed quality control. Correction: Because stove piping can be caused
Correction: If you experience a squib while by the firearm, ammunition, or operator, the
shooting, stop immediately. Firing another cause needs to be determined. Use different
round may cause a pressure spike that could brands of ammunition to see if the problem per-
blow the firearm apart. Unload the firearm and sists. Also, thoroughly cleaning and lubricating
make certain there is not a bullet stuck in the the firearm may help to alleviate any issues.
bore. If the bore is unobstructed, discontinue the Limp wristing can be cured with a proper grip.
use box/case/lot of ammunition you are using. Getting the shooting and support hands as
If there is an obstruction in the bore, it must be high up against the bore axis of the firearm will
removed. You need to determine the safest and prevent the muzzle from flipping excessively.
easiest way to remove the obstruction. If you can Locking your wrists and gripping the firearm
remove the barrel, then it is recommended that with enough force so that it does not slip in
you do so. You want to push the obstruction out your hands will also cure any issues. Also, the
of the path of least resistance, meaning you want

181
Figure 1.6- A stovepipe (1) is most often associated with
limp wristing. To clear a stovepipe, initiate the safety
and remove the magazine (2). Manipulate the slide until
all loose rounds are free of the firearm (3). This same
procedure can be used to clear a stovepipe in any type of
repeating, magazine-fed firearm. The only difference is
in the names of the action parts (bolt/charging/operating
handle or slide).

use of isometric tension will aid in securing the

firearm and controlling recoil.
If the problem continues, then the firearm
is most likely the cause. There may be burrs,
scratches or damaged action parts. Remove any
burrs, polish out any rough spots or scratch-
es, repair or replace broken or damaged parts
and worn springs. Pay special attention to the
chamber, extractor and ejector. A rough cham-
ber may cause extraction issues. Damaged ex-
tractors, ejectors, and springs may also lead to
stove piping. Repair and replace parts as needed
(Figure 1.6).

182
NOTES
NOTES