TECHNICAL MANUAL

DENNIS J. REIMER General, United States Army Chief of Staff

Official:

JOEL B. HUDSON

Administrative Assistant to the

Secretary of the Army

03287

DISTRIBUTION: To be distributed in accordance with the initial distribution number (IDN) 400020, requirements for TM 9-1005-319-23&P.

UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) RIFLE, 5.56MM, M16A2 W/E (1005-01-128-9936) (EIC:4GM)

TM 9-1005-319-23&P, May 1991, is changed as follows:

Remove Pages

4-1 and 4-2 4-9 thru 4-11/(4-12 blank) A-1 and A-2 B-5 thru B-8 C-1 and C-2 C-7 and C-8/(C-9 blank) Fig C-1 thru Fig C-2 C-5-1 thru Fig C-9 C-10-1 thru C-11-2 C-12-1 thru Fig C-17-1 I-1 thru 1-10 D-3 and D-4 E-5/(E-6 blank) Cover

Insert Pages

4-1 and 4-2 4-9 thru 4-11/(4-12 blank) A-1 and A-2 B-5 thru B-8 C-1 and C-2 C-7 and C-8/(C-9 blank) Fig C-1 thru Fig C-2 C-5-1 thru Fig C-9 C-10-1 thru C-11-2 C-12-1 thru Fig C-17-1 1-1 thru 1-12 D-3 thru D-5/(D-6 blank) E-5 and E-6 Cover

4. File this change sheet in the front of the publication for reference purposes.

GORDON R. SULLIVAN General, United States Army Chief of Staff

JOEL B. HUDSON Acting Administrative Assistant to the Secretary of the Army 00175

DISTRIBUTION: To be distributed in accordance with DA Form 12-40-E, block 0020 requirements for TM 9-1005-319-23&P.

UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) RIFLE, 5.56MM, M1 6A2 W/E (1005-01-128-9936) (EIC:4GM)

TM 9-1005-319-23&P, May 1991, is changed as follows:

Remove Pages Insert Pages

a thru iv/v(blank)

GORDON R. SULLIVAN General. United States Army Chief of Staff

Official

MILTON H HAMILTON

Administrative Assistant to the

Secretary of the Army

05909

DISTRIBUTION: To be distributed in accordance with DA Form 12-40-E, Block 0020, requirements for TM 9-1005-319-23&P.

CHANGE HEADQUARTERS DEPARTMENTS OF THE ARMY No. 2 AND AIR FORCE Washington, DC 17 AUGUST 1992

UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) RIFLE, 5.56MM, M16A2 W/E (1005-01-1 28-9936) (EIC:4GM)

TM 9-1005-319-23&P, May 1991, is changed as follows:

1. Remove old pages and insert new pages as indicated below.

2. New or changed material is indicated by a vertical bar adjacent to the material.

3. New or changed illustrations are indicated by a miniature pointing hand highlighting the change.

Remove Pages Insert Pages

1-3 and 1-4 1-3 and 1-4

4. File the change sheet in the front of the publication for reference purposes.

GORDON R. SULLIVAN General. United States Army Chief of Staff

Official

MILTON H HAMILTON

Administrative Assistant to the

Secretary of the Army

By Order of the Secretary of the Air Force: MERRILL A. McPEAK, General USAF Chief of Staff

Offical:

CHARLES C. McDONALD, General, USAF Commander, Air Force Logistics Command

DISTRIBUTION: TO BE DISTRIBUTED IN ACCORDANCE WITH DA FORM 12-40-E, (BLOCK 0020), REQUIREMENTS FOR TM 9-1005-319-23&P.

Washington, DC 2 April 1992

UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) RIFLE, 5.68MM, M16A2 W/E (1005-01-128-9936) (EIC:4GM)

TM 9-1005-319-23&P, May 1991, Is changed as follows:

GORDON R. SULLIVAN

General. United States Army

Chief of Staff Official

MILTON H HAMILTON Administrative Assistant to the Secretary of the Army

DISTRIBUTION:

To be distributed in accordance with DA Form 12-40-E, (Block 0020), Unit, Direct and General Support Maintenance requirements for TM-9-1005-319-23&P.

WARNING

ALL WARNINGS in this technical manual pertain to both the rifle and the carbines unless otherwise specified.

Before starting an inspection, be sure to clear the rifle. Do not pull the trigger until the rifle has been cleared. Inspect the chamber to ensure that it is empty and no ammunition is in position to be chambered.

Do not keep live ammunition near work area.

To avoid injury to your eyes, use care when removing and installing spring-loaded parts.

All M1 6A2 rifles and M4 carbines must be inspected and gaged at least once annually for safety and serviceability. Initial gaging is required 1 year from receipt of the weapons. Air Force users refer to inspection requirements in Air Force Manual (AFM) 36-2227, Volume 1.

All Army Reserve and Army National Guard M16A2 rifles and M4 carbines must be inspected and gaged at least once every 2 years, after the initial inspection/gaging procedures have been accomplished. This initial gaging procedure is required 1 year from receipt of the weapons. This 2 year interval may be maintained unless preventive maintenance checks and services (PMCS) or other physical evidence indicates that an individual unit’s M16A2 rifles and M4 carbines require inspection/ gaging at a more frequent interval. If it is determined that a yearly inspection is necessary for an individual unit, only that unit will be affected. This will not affect other units in regard to the interval of inspection.

It is recommended that training units inspect/gage all rifles and carbines at the end of each training cycle. Training units will inspect/gage all rifles and carbines at least once annually.

Below direct support maintenance, DO NOT interchange bolt assemblies from one rifle/carbine to another. Doing so may result in injury to, or death of, personnel.

Bolt cam pin must be installed or rifle/carbine will blow up while firing the first round. If the bolt cam pin is not installed, injury to or death of, personnel may result.

Dry cleaning solvent is flammable and toxic and should be used in a well ventilated area. The use of rubber gloves is necessary to protect the skin when washing rifle parts.

When using solid film lubricant or dichloromethane, be sure the area is well ventilated.

When using carbon removing compound (item 8, app D), avoid skin contact. If carbon removing compound comes In contact with the skin, wash thoroughly with running water. using a good lanolin base cream after exposure to the compound is helpful. Using gloves and protective equipment is required.

The lock plate prevents the selector lever from being placed in BURST and will be installed at the discretion of the unit commander. It is mandatory for use in civil disturbance (riot control).

Only blank cartridge M200 is to be used when the blank firing attachment is attached to the rifle/carbine.

Change 5 a ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

WARNING (CONT)

Do not fire blank ammunition at a representative enemy at distances of less than 20 feet (6.10 Om). The unburned

propellant grains can cause injury within this distance. For further information on safety, care, and handling of ammunition: Army and Air Force users refer to M16A2 Rifle Operator’s Manual.

For additional first aid data, see Field Manual (FM) 21-11. b

DISTRIBUTION STATEMENT. APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED. REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures please let us know.

Army users mail your letter, DA Form 2028 (recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual direct to: Director, Armament and Chemical Acquisition and Logistics Activity, ATTN: AMSTA-AC-NML, Rock Island, IL 61299-7630.

Air Force users submit AFTO Form 22, Technical Order System Publication Improvement Report and Reply, to: WR-ALC/MMDET, Robins AFB, GA 31098-5609.

A reply will be furnished to you.

Page

*This manual supersedes ARMY TM 9-1005-319-23&P dated 28 August 1987, including all changes.

Change 5

Illus Page Figure APPENDIX C. REPAIR PARTS AND SPECIAL TOOLS LIST--Cont.

Change 4 ii.1/(ii.2 blank)

HOW TO USE THIS MANUAL

GENERAL

There are several things you need to know to use this manual efficiently.

1. All references in the manual are to pages only. Reference to maintenance procedures is to the page where the respective initial setup appears.

1. Illustrations for the maintenance procedures show only those parts affected by the operation being performed.

2. Whenever the male gender is mentioned in the manual (i.e., crewman, repairman), it also pertains to females.

3. When the term “evacuate to support maintenance” is used, the entire rifle must be evacuated.

1. When a procedure is common to M16A2 rifle, and M4/M4A1 carbine, ONLY the M16A2 configuration will be depicted. If a procedure is not common to both weapons, the procedure will be incorporated.

6. When the word rifle is referenced in text, it will reference the rifle and the carbines.

INDEXES

This manual is organized to help you find the information you need quickly. There are several useful indexes.

1. Table of Contents. Lists in order all chapters, sections, and appendixes. Gives page references.

2. Nomenclature Cross-References List.

3. Chapter Overviews. Summarize material covered in the chapter. Are located at the beginning of each chapter.

1. Symptom Index. Located just before the troubleshooting table in each maintenance chapter. Lists, in alphabetical order, parts of the rifle with possible malfunctions. References pages of the troubleshooting table.

2. Alphabetical Index. Located at the end of the manual. An extensive subject index for everything in the manual. Gives page references.

MAINTENANCE PROCEDURES

There are two maintenance chapters: Army personnel use chapter two for unit maintenance procedures and chapter three for direct support maintenance procedures. Change 4 iii

Air Force personnel: Only Air Force Specialty Code 753XX Combat Arms Training and Maintenance (CATM) specialists, technicians, and gunsmiths are authorized to perform maintenance procedures contained in this manual.

Each maintenance task has an initial setup containing a list of the following things you will need in order to do your maintenance task.

1. Tools and Special Tools. For standard and special tools, see appendixes B and C. Army users are to use the Tool Set, Gage Set, and/or Shop Set listed in the initial setup.

1. Materials/Parts. Lists expendable materials and 100 percent replaceable parts. Each material or part is followed by a part number or appendix reference.

2. 3. References. Lists other publications containing necessary information.
2. Equipment Condition. Lists conditions to be met before starting the procedure. The reference on the left of the condition is a page reference to instructions for setting up the condition.

3. General Safety Instructions. Lists safety instructions to follow before performing maintenance procedures. iv/(v blank) Change 3

EXTERNAL VIEW OF 5.56 MM RIFLE M16A2

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

EXTERNAL VIEW OF 5.56MM CARBINE, M4/M4A1

Change 4 1-0.1/(1-0.2 blank)

CHAPTER 1 INTRODUCTION

This chapter contains general information, equipment description and data, and principles of operation for the M16A2 rifle and M4/M4A1 carbines.

Section I. GENERAL INFORMATION 1-1. SCOPE.

a.

Type of Manual: Unit and Direct Support Maintenance.

b.

Model Number and Equipment Name: 5.56mm Rifle M16A2, M4 and M4A1 Carbines.

c.

Purpose of Equipment. Provides personnel an offensive/defensive capability to engage targets with small arms fire.

1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS. Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 738-750, The Army Maintenance Management System. Air Force users refer to TO 11W-1-10 for applicable forms and records.

1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE. See TM 750-244-7. 1-4. PREPARATION FOR STORAGE OR SHIPMENT. Refer to page 2-70.

Air Force users refer to Special Package Instruction (SPI) 00-856-6885.

1-5. OFFICIAL NOMENCLATURE, NAMES AND DESIGNATIONS. NOMENCLATURE CROSS-REFERENCE LIST Common Name Official Nomenclature

Action Spring ................................................................... Compression Helical Spring Ball Bearing ..................................................................... Bearing Ball Bolt Catch Spring............................................................. Compression Helical Spring Bolt Carrier Key Tool ....................................................... Machine Key Burst Disconnector .......................................................... Lock-Release Lever Cam Clutch Spring .......................................................... Helical Spring Carbine ............................................................................ M4/M4A1 Carbine Charging Handle Assembly ............................................. Handle Assembly

Change 5 1-1

1-5. OFFICIAL NOMENCLATURE, NAMES AND DESIGNATIONS (CONT).

NOMENCLATURE CROSS-REFERENCE LIST

Common Name Official Nomenclature

Disconnector Springs ...................................................... Compression Helical Spring Ejector Spring .................................................................. Helical Spring Extractor Spring Assembly .............................................. Spring Assembly Hammer Spring ............................................................... Torsion Helical Spring Lower Receiver Extension............................................... Spring Receiver Holder Magazine ......................................................................... Cartridge Magazine Magazine Catch Spring ................................................... Compression Helical Spring Peel Washer .................................................................... Shim Pistol Grip ........................................................................ Rifle Grip Pivot Pin Detent............................................................... Takedown Pin Detent Rifle ................................................................................. Rifle, 5.56mm, M16A2 Rifle Barrel Assembly ...................................................... Barrel Assembly Selector Lever ................................................................. Fire Control Selector Semiautomatic Disconnector........................................... Lock-Release Lever Sling................................................................................. Small Arms Sling Trigger Spring.................................................................. Torsion Helical Spring Upper Receiver................................................................ Upper Cartridge Receiver

1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR). If your M16A2 rifle needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design.

Army users submit SF 368 (Product Quality Deficiency Report) to: Commander, U.S. Army Armament Research, Development and Engineering Center, ATTN: AMSTA-AR-QAW (R)/Customer Feedback Center, Rock Island, IL 612997300.

Air Force users submit Materiel Deficiency Report (MDR) to: DIR MAT MGT ROBINS AFB GA//MMIBTC// and Product Quality Deficiency Report to: DIR MAT MGT ROBINS AFB GA//MMQA// IAW Technical Order 00-35D-54.

A reply will be sent to you.

1-7. CORROSION PREVENTION AND CONTROL (CPC). CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items,

While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.

1-2 Change 4 If a corrosion problem is identified, it can be reported using Standard Form 368, Product Quality Deficiency Report. Use of key words such as "corrosion", "rust", " deterioration", or "cracking" will assure that the information is identified as a CPC problem.

Army users submit Product Quality Deficiency Report (SF 368) to:

Commander

U.S. Army Armament Research, Development and Engineering CenterATTN: AMSTA-AR-QAW (R) Rock Island, IL 61299-7300

Air Force users submit Materiel Deficiency Report (MDR) to:

DIR MAT MGT ATTN: MMIBTC Robins AFB, GA

and Product Quality Deficiency Report to:

DIR MAT MGT ATTN: MMQA Robins AFB, GA

Section II. EQUIPMENT DESCRIPTION AND DATA

1-8. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.

a. Characteristics.

(1)

Receivers are made of light-weight aluminum alloys; however, the safety , durability, and function of the rifles are in no way reduced. The portability and logistical values are greatly increased, particularly when air transport is used.

(2)

The bolt locking action is one of the mechanical features of the rifle. The bolt assembly and barrel extension contain locking lugs which engage and lock the bolt assembly firmly in the barrel extension. The initial force of the explosion of the cartridge is absorbed by the barrel, barrel extension, and bolt assembly.

Change 4 1-3

1-8. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (CONT).

(3)

The trigger guard is easily adaptable to winter operations. A spring-loaded retaining pin is depressed to allow ready access to the trigger when wearing arctic mittens.

(4)

The ejection port cover prevents dirt or sand from getting into the ejection port. The ejection port cover must be closed during periods when firing is not anticipated. It opens automatically by the forward or rearward movement of the bolt carrier assembly.

1-9. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.

(A)

MAGAZINE. 30 cartridge capacity.

(B)

SLING. The sling is adjustable and provides a means to carry the weapon.

(C)

BOLT CARRIER ASSEMBLY. Carries bolt assembly to chamber and fires the weapon. Contains the firing pin, cartridge extractor, bolt assembly, cartridge ejector, and bolt cam pin.

(D)

CHARGING HANDLE ASSEMBLY. Provides a means of charging the weapon.

(E)

M16A2 UPPER RECEIVER AND BARREL ASSEMBLY. Upper receiver contains rear sight assembly, ejection port, ejection port cover, and a housing for the key and bolt carrier assembly and bolt assembly. Rifle barrel assembly is air-cooled, contains compensator and front sight assembly, and holds the two handguard assemblies and the sling swivel.

(F)

LOWER RECEIVER AND BUTTSTOCK ASSEMBLY. Lower receiver contains the trigger assembly, sear, hammer assembly, selector lever, rifle grip, bolt catch, and buttstock assembly. The buttstock assembly houses the action spring, buffer assembly, and extension assembly.

(G)

M4/M4A1 CARRYING HANDLE. Provides a means of carrying carbine.

(H)

M4/M4A1 UPPER RECEIVER AND BARREL ASSEMBLY. Upper receiver contains, ejection port, ejection port cover, a housing for key and bolt carrier assembly and bolt assembly, and mounting surface for the carrying handle assembly. Carbine barrel assembly is air-cooled, contains compensator and front sight assembly, and holds the two handguard assemblies and the sling swivel.

1-4 Change 4

Change 4 1-4.1

1-10. EQUIPMENT DATA.

Weight: Carbine, M4/M4A1 without magazine and sling ...... Rifle, Ml 6A2 without magazine and sling................ Sling, adjustable ...................................................... Empty magazine ...................................................... Loaded magazine .................................................... Carbine, M4/M4A1 w/sling and loaded magazine ... Rifle M16A2 w/sling and loaded magazine.............. Bayonet-Knife M7 .................................................... Scabbard M10 o ......................................................

Length: Carbine with compensator, buttstock extended....... Carbine with compensator, buttstock closed ........... Rifle with compensator ............................................ Barrel (Carbine) ....................................................... Barrel (Rifle)............................................................. Barrel with compensator (Carbine) .......................... Barrel with compensator (Rifle) ...............................

Mechanical features:

US CUSTOMARY METRIC

6 lb 7 oz 2.91 kg 7 lb 8 oz 3.40 kg 4 oz 0.11 kg 4 oz 0.11 kg 1 lb 1 oz 0.48 kg 7 lb 12 oz 3.51 kg 8 lb 13 oz 4.00 kg

10.5 oz 0.30 kg 5 oz 0.14 kg

33.0 in 83.82 cm

29.75 in 75.57 cm

39.63 in 100.66 cm

14.5 in 36.83 cm 20 in 50.8 cm

15.5 in 39.37 cm 21 in 53.34 cm

Rifling....................................................................... right-hand twist 6 grooves, 1 turn

................................................................................. Method of operation................................................. Type of breech mechanism ..................................... Method of feeding .................................................... Cooling..................................................................... Trigger pull (M16A2 & M4)....................................... Trigger pull (M4A1) ..................................................

Ammunition: Caliber .....................................................................

in 7 inches (17.78 cm) direct gas rotating bolt magazine air

5.5 to 9.5 lb

5.5 to 8.5 lb

223 2.49 to 4.31kg

2.49 to 3.86 kg 5.56mm

Type......................................................................... ball, blank, dummy, and tracer

Firing characteristics: Muzzle velocity (Carbine) (approximate) ................. Muzzle velocity (Rifle) (approximate)....................... Chamber pressure ...................................................

Cyclic rate of fire (Carbine) (approximate)............... Cyclic rate of fire (Rifle) (approximate) ....................

1-4.2 Change 5 2,970 fps 3,100 fps 52,000 psi

700-970 rds/m 700-900 rds/m 905.85 mps 945.5 mps 358,540 kPa

Maximum rate of fire: Semiautomatic ......................................................... Burst ........................................................................ Sustained rate of fire ............................................... Maximum range .......................................................

Maximum effective range: Individual/point targets (Carbine)............................. Individual/point targets (Rifle) .................................. Area targets (Carbine) ............................................. Area targets (Rifle) ..................................................

US CUSTOMARY

45 rds/m

90 rds/m

12/15 rds/m

3,938 yards

547 yards 602 yards 650 yards 875 yards

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

METRIC

Approximately 3,600 meters

500 meters 550 meters 600 meters 800 meters

Section III. PRINCIPLES OF OPERATION 1-11. GENERAL. The 5.56mm M16A2 and M4/M4A1 carbine:

a. Is gas-operated. It fires in either the semiautomatic or burst mode.

b. Has positive locking of the bolt. Firing pin is part of the bolt carrier assembly and cannot strike the primer until the bolt assembly is fully locked.

Change 4 1-5 ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

Section III. PRINCIPLES OF OPERATION (CONT). 1-12. PRINCIPLES OF OPERATION.

(A)

MAGAZINE. Holds cartridges ready for feeding and provides a guide for positioning cartridges for stripping. Provides quick reload capabilities for sustained firing.

(B)

SLING. Provides the means for carrying the weapon.

(C)

BOLT CARRIER ASSEMBLY. Provides stripping, chambering, locking, firing, extraction, and ejection of cartridges using the drive springs and projectile propelling gases for power.

(D)

CHARGING HANDLE ASSEMBLY. Provides initial charging of the weapon. The handle latch locks the charging handle assembly in the forward position during sustained fire to prevent injury to the operator.

(E)

M16A2 UPPER RECEIVER AND BARREL ASSEMBLY. Provides support for the bolt carrier assembly. The barrel chambers the cartridge for firing and directs the projectile.

(F)

LOWER RECEIVER AND BUTTSTOCK ASSEMBLY. Provides firing control for the rifle and carbine. M16A2 ONLY provides storage for basic cleaning materials.

(G)

M4/M4A1 CARRYING HANDLE ASSEMBLY. Provides a means of carrying the carbine, contains rear sight assembly, and can be removed for mounting various optics.

(H)

M4/M4A1 UPPER RECEIVER AND BARREL ASSEMBLY. Provides support for the bolt carrier assembly. The barrel chambers the cartridge for firing and directs the projectile.

1-6 Change 5

CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS

This chapter provides information and Instructions to help keep the rifle in good repair and contains the following sections:

a.

Repair Parts, Special Tools, TMDE, and Support Equipment

b.

Service Upon Receipt

c.

Preventive Maintenance Checks and Services (PMCS)

d.

Troubleshooting

e.

Maintenance Procedures

Section I. REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

2-1. COMMON TOOLS AND EQUIPMENT. For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE) applicable to your unit.

Air Force users must maintain the following common tools:

3-ounce soft-brass hammer Vise Flat tip screwdriver Punch

Tweezers/round nose pliers Hammer Needle nose pliers

2-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT. Special tools required for unit support are listed in appendixes B and C. Fabricated tools are listed and illustrated in appendix E.

2-3. REPAIR PARTS. Repair parts are listed and illustrated in appendix C of this manual.

Section II. SERVICE UPON RECEIPT

2-4. GENERAL.

a.

Inspect the rifle for damage Incurred during shipment. If rifle has been damaged, report the damage on SF 364, Report of Discrepancy (ROD).

b.

Check the rifle against the packing slip to see If shipment is complete. Army users report all discrepancies in accordance with DA PAM 738-750.

Air Force users submit Materiel Deficiency Report (MDR) to: DIR MAT MGT ROBINS AFB GA//MMIBTC// and Product Quality Deficiency Report to: DIR MAT MGT ROBINS AFB GA//MMQA//. IAW Technical Order 00-35D-54.

c. Check to see whether the equipment has been modified.

2-5. SERVICE UPON RECEIPT OF MATERIEL.

WARNING

Before starting an inspection, be sure to clear the rifle. Do not actuate the trigger before clearing the rifle. Inspect the chamber to make sure it is empty and free of obstructions. Check to see there are no obstructions in the barrel and no ammunition is in position to be chambered.

SERVICE UPON RECEIPT

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

SERVICE UPON RECEIPT (CONT)

Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

2-6. GENERAL This section contains the procedures and instructions necessary to perform unit preventive maintenance checks and services. These services are to be performed by unit maintenance personnel with the assistance of the operator where practical.

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

WARNING

Before starting an inspection, be sure to clear the rifle. Do not keep live ammunition near the work area.

a.

General. The PMCS procedures are contained in the table following. They are arranged in logical sequence requiring a minimum amount of time and motion on the part of the persons performing them and are arranged so that there will be minimum interference between persons performing checks simultaneously on the same end item.

b.

Item No. Column. Checks and services are numbered in disassembly sequence. This column shall be used as a source of item numbers for the "TM Number" column on DA Form 2404, Equipment Inspection and Maintenance Worksheet, in recording results of PMCS.

c.

Interval Column. This column gives the designated interval when each check is to be performed.

d.

Item To Be Checked Or Serviced Column. This column lists the items to be checked or serviced.

e.

Procedure Column. This column contains a brief description of the procedure by which the check is to be performed. It contains all the information required to accomplish the checks and services. Information marked SH Indicates a specific equipment shortcoming and the procedure needed to correct the shortcoming.

NOTE

For the purpose of this technical manual, the following definition is supplied. This definition is not intended to apply to any other document

Shortcoming (SH): A fault that requires maintenance or supply action on a piece of equipment, but does not render equipment Not Mission Capable

f. Not Fully Mission Capable If: Column. This column contains a brief statement of the condition (e.g., malfunction, shortage) that would cause the covered equipment to be less than fully ready to perform its assigned mission.

Change 3 2-3

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTION MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT) PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT) PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

2-7.1/(2-7.2 blank)

Change 4

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT) PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

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2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT) PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT) PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

2-13 Change 3

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT) PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

2-16 Change 5

PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONS). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT) PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT). PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE (CONT)

Section IV. TROUBLESHOOTING 2-8. GENERAL.

a.

This section contains unit level troubleshooting information for locating and correcting most of the operating troubles which may develop in the M16A2 rifle, M4/M4A1 carbine. Each malfunction for the individual part or assembly is followed by a list of tests or inspections which will help you to determine the corrective actions in the order listed.

b.

This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed or is not corrected by listed corrective actions, see individual repair sections in the maintenance procedures on each major assembly.

2-9. TROUBLESHOOTING PROCEDURES. Refer to troubleshooting table for malfunctions, tests, and corrective actions. The symptom index is provided for a quick reference of the malfunctions covered in the table.

2-20 Change 4

ARMY TM 9-1005 319-23&P AIR FORCE TO 11W3 5-5-42

SYMPTOM INDEX

Troubleshooting Procedures

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

1. FAILURE OF MAGAZINE TO LOCK IN RIFLE. Step 1. Dirty or corroded magazine catch (1). Disassemble and clean. Step 2 Defective magazine catch spring (2) Evacuate to support maintenance.

Step 3 Worn or broken magazine catch (1). Evacuate to support maintenance

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-9. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

1. FAILURE TO FEED Step 1. Magazine catch spring weak or broken Evacuate to support maintenance Step 2. Magazine catch (1) defective. Evacuate to support maintenance Step 3. Magazine catch (1) out of adjustment (will not retain magazine) Refer to operator’s manual.

2. Step 4. Short recoil. Refer to page 2-28
1. FAILURE TO CHAMBER.

Step 1. Weak or broken action spring (1), RIFLE ONLY (free length 11 3/4 inches (29.85 cm) minimum to 13 1.’2 Inches (34 29 cm) maximum) CARBINE ONLY (10 1 16 inches (2S 56 cm) minimum to 11 1,4 inches (28 58 cm) maximum)

Replace action spring (p 2-57)

2-22 Change 3

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

Step 3. Improperly assembled extractor spring assembly (3) Assemble correctly (p 2-38).

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-9. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

4. FAILURE TO LOCK (CONT) Step 4. Bent gas tube 14J a Adjust to Its original configuration by bending in area of hand-guard assembly.

b If the gas tube cannot be returned to Its original configuration, evacuate the rifle to support maintenance

Step 5 Weak or broken action spring (5); RIFLE ONLY: (free length 11 3/4 inches (29,85 cm) minimum to 13 1,/2 Inches (34 29 cm) maximum). CARBINE ONLY (10 1/16 Inches (25 56 cm) minimum to 11 1,4 inches (28 58 cm) maximum

Replace action spring (p 2-571

2-24 Change 3

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

Step 2 Carbon buildup in firing pin recess inside bolt assembly Remove cartridge extractor and clean recess with pipe cleaner (Item 11, app D), refer to operator’s manual. Step 3. Firing mechanism (2) and or lower receiver assembly (31 improperly assembled or has worn, broken, or missing parts. Evacuate to support maintenance Step 4. Broken, defective, or missing firing pin retaining pin (4). Replace (p 2-35) Step 5. Selector lever (5) frozen on SAFE position. Evacuate to support maintenance

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-9. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

1. FAILURE TO UNLOCK. Step 1. Burred locking lugs (1) on bolt assembly. Remove burrs. Step 2. Burred lugs (2) on barrel extension Remove burrs.

2. Step 3 Short recoil. Refer to page 2-28.
1. FAILURE TO EXTRACT. Step 1. Defective extractor pin (1), cartridge extractor (2), and or extractor spring assembly (3). Replace extractor pin (1), cartridge extractor (2), and or extra(:tor spring assembly (3) (p 2-381

Step 2. Short recoil Refer to page 2-28

NOTE

Rubber insert and spring are an assembly Illustration shows Insert out of assembly for clarification only Do not remove the rubber Insert from the extractor spring assembly.

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

8. FAILURE TO EJECT. Step 1. Broken cartridge ejector (1). Replace (p 2-38). Step 2. Cartridge ejector (1) stuck in bolt body (2). Disassemble and clean (p 2-38). Step 3. Weak or broken ejector spring (3). Replace (p 2-38)

Step 4. Short recoil Refer to page 2-28.

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-9. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

9. FAILURE TO COCK Step 1 Worn, broken, or missing parts of firing mechanism Evacuate to support maintenance. Step 2 Short recoil Refer to below 10 SHORT RECOIL Step 1 Broken or damaged action spring (1). Replace action spring (p 2-57).

Step 2 Unlubricated or dirty action spring and receiver extension Clean and lubricate

Step 3 Improper gap space or worn, missing, or broken bolt rings (2)

a.

Stagger bolt ring gaps (approximately 13 turn apart}

b.

Evacuate to support maintenance if bolt rings are worn, broken, or missing.

2-28 Change 3

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

Step 4. Carbon build-up or foreign matter In the narrow passage of the bolt carrier key (3).

Clean with CLP (Item 9, app D) and a pipe cleaner (Item 11, app D).

Step 5. Gas leakage caused by broken or loose gas tube (4) around front sight base.

Evacuate to support maintenance.

Step 6. Improper alignment of gas tube and carrier key.

a.

Adjust gas tube alignment by bending in area of handguard assembly to Its original configuration

b.

If gas tube cannot be returned to Its original configuration, evacuate the rifle to support maintenance.

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-9. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

11. RIFLE CANNOT BE ZEROED. Step 1. Defective barrel assembly (1). Evacuate to support maintenance Step 2. Barrel assembly out of alignment with rear sight assembly (2) on upper receiver. Evacuate to support maintenance Step 3. Defective front sight (3). Remove front sight post (4), front sight detent (5), and helical spring (6). If damaged, replace.

Step 4. Defective -ear sight assembly (2). Evacuate to support maintenance.

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

12. FAILURE TO CYCLE WITH SELECTOR LEVER SET ON BURST (M16A2 AND M4).

Faulty selector lever or broken cam, cam clutch spring, or burst disconnector. Evacuate to support maintenance.

1. FAILURE TO CYCLE WITH SELECTOR LEVER SET ON AUTO (M4A1).

2. Faulty selector lever. Evacuate to support maintenance.
1. FIRES TWO ROUNDS WITH ONE PULL OF TRIGGER WITH SELECTOR LEVER SET ON SEMI (DOUBLE FIRING).

Perform function test.

If any part of function test (p 2-68) fails, evacuate to support maintenance.

14. FIRES WITH SELECTOR LEVER ON SAFE OR WHEN TRIGGER IS RELEASED WITH SELECTOR LEVER ON SEMI.

Worn, broken, or missing parts of firing mechanism. Evacuate to support maintenance.

Change 4 2-31

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

2-9. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

15 BOLT ASSEMBLY FAILS TO LOCK TO REAR AFTER FIRING LAST ROUND. Step 1. Magazine follower (1) worn or broken. Replace magazine.

Step 2. Magazine catch spring (2) weak or broken. Replace magazine.

Step 3. Magazine feeder lips (3) bent or broken. Replace magazine.

Step 4. Magazine follower (1) binds during operation. Replace magazine.

Step 5. Broken bolt catch (4) and/or spring. Evacuate to support maintenance.

2-32 Change 5

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

Section V. MAINTENANCE PROCEDURES

2-10. INITIAL SETUP. The following information will reduce the space required for the initial setup portion of the maintenance procedures.

a. Materials/Parts required are not listed unless they apply to the procedure

b.

Personnel Required is listed only if the task requires more than one person If Personnel Required Is not listed, It means one person can do the job.

c.

The normal standard equipment condition Is that the item is removed from the en(1 Item or next higher assembly and is in the assembled condition. Equipment Condition is not listed unless some other condition is required.

d. The approximate time required Is listed on the applicable Maintenance Allocation Chart (MAC).

e.

When the term evacuate to support maintenance is used, the entire rifle must be evacuated. 2-11. LUBRICATION GENERAL.

a.

Whenever the term "cleaner, lubricant, and preservative (CLP)" or the words "lubricant", "lube", "LSA", or "LAW" are cited In this TM, they are to be interpreted to mean CLP (Item 9, app D), weapons lubricating oil (LSA) (Item 23, app D), or weapons lubricating oil (LAW) (Item 22, app D) can be utilized as applicable The following constraints must be adhered to:

b.

Under all but the coldest arctic conditions, LSA or CLP are the lubricants to use on the rifle. Either may be used at 100F (230C) and above. However, do not use both on the same rifle at the same time.

c.

LAW is the lubricant to use during cold arctic conditions, + 100F (12C) and below

d.

Any of the lubricants may be used from 10°F to + 100F (230C to 12°C)

e.

ARMY ONLY: Do not mix lubricants on the same rifle The rifle must be thoroughly cleaned during change from one lubricant to another Dry Cleaning Solvent (SD) (Item 16, app D) is recommended for cleaning during change from one lubricant to another.

f.

Rifle Bore Cleaner (RBC) (item 12, app D) may be used to remove carbon buildup In the bore and other portions of the rifle.

2-33

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

12-13. BOLT CARRIER ASSEMBLY.

Change 5 2-35

a. DISASSEMBLY

NOTE

Do not separate cartridge extractor and extractor spring assembly unless replacement of either or both is required

Do not remove the rubber Insert from the extractor spring assembly

1. Push out extractor pin (1) and remove cartridge extractor (2) and extractor spring assembly (3) as a unit

2. If required, twist extractor spring assembly (3) counterclockwise to remove from cartridge extractor (2).

CAUTION

Be sure to use vise law protective caps

3. Hold bolt body In vise and remove spring pin

(4) using 1 16 Inch punch and hammer

WARNING

To avoid injury to your eyes, use care when removing and installing spring-loaded parts.

4. Remove punch, be sure to catch cartridge elector (5) and ejector spring (6) to prevent loss

2-40

2-42

2-43

2-15. CHARGING HANDLE ASSEMBLY (CONT).

b. CLEANING

Clean all Items (operator’s manual) Remove carbon deposits.

c. INSPECTION/REPAIR

Inspect all Items for breaks, cracks, or damage Replace all unserviceable Items

d. LUBRICATION

Lightly lubricate all Items (p 2-33) (operator’s manual)

e. REASSEMBLY

1. Position helical spring I1) and charging handle latch (2) in chdrgiin(J handle 13) Align holes and hold In position

2. Install spring pin (4) using a hammer Make sure spring pin is flush

3. Reassemble rifle, refer to page 2 68

This task covers:

a.

Disassembly e. Lubrication

b.

Cleaning f. Reassembly

c.

Inspection

d.

Repair

INITIAL SETUP

Tools References (ARMY) Small Arms Repairman Tool Kit TM 9-1005-319-10 (operator’s manual) (item 3, app B) Front sight post removal and installation Equipment Conditions tool (fig. E-2, app E) 2-34 Upper receiver and barrel assembly Front sight detent depressor (fig. E-1, removed from lower receiver app E) General Safety Instructions Materials/Parts To avoid injury to your eyes, use care Lubricants (app D) when removing and installing spring-loaded parts.

a. DISASSEMBLY

CAUTION Do not use a screwdriver or any other tool when removing the handguard assemblies. Doing so may damage the handguard assemblies and/or slip ring. Do not remove heat shield for any reason. Doing so will damage the heat shield and the handguard assemblies will have to be replaced.

NOTE

Refer to operator’s manual for "buddy system" procedure on removing handguard assemblies.

UPPER RECEIVER ASSEMBLY (CONT).

NOTE Remove front sight posts only if parts are damaged.

3. Using a dummy cartridge or a font sight post removal and installation tool (4).removed front sight post (6) by turning counter clockwise.

2-47.1 (2-47.2 blank) Change 3

a. DISASSEMBLY (CONT)

NOTE

Do not disassemble further unless repair is necessary. Headless grooved pin (11) may bind may bind against the forward assist housing and require some additional force to remove.

1. Remove retaining ring (12) and slide headles grooved pin (11) out to the rear.

2. Catch cover spring (13) and ejection port cover (14) to prevent loss as headless grooved pin is with-drawn.

2-48 Change 4

b. CLEANING

Clean all items (operator’s manual).

Change 4 2-48.1/(2-48.2 blank)

c. INSPECTION

1. Inspect front sight assembly for chips, breaks, and cracks. Evacuate to support maintenance if broken, cracked, or bent.

2. Inspect front sight area for evidence of gas leakage around gas tube. Evacuate to support maintenance if short recoil results from gas leakage.

3. Inspect front sight post, front sight detent, and helical spring for damage. If damaged, replace.

Change 5 2-49

2-51

Change 4 2-53

2-53.1/(2-53.2 blank) Change 3

t. REASSEMBLY (CONT)

b. Using a dummy round or front sight post tool adjust the front sight so the top of the front sight post is 5mm above the machined surfaces of the front sight frame.

2-54 Change 4

2-55

Change 5 2-57

2-58 Change 3

Change 3 2-58.1/(2-58.2 blank) Clean all items (operator’s manual). Remove carbon deposits

Change 4 2-59

2-60 Change 3

d. REPAIR

Change 4 2-61

f. REASSEMBLY

WARNING

To avoid Injury to your eyes, use care when removing and Installing spring loaded parts.

NOTE Make sure the hammer Is cocked and the selector lever is not set on BURST before Installing the buffer assembly.

Change 3 2-63

f. REASSEMBLY (CONT)

2-63.1/(2-63.2 blank) Change 3

Change 3 2-65

b. CLEANING (RIFLE ONLY)

Clean all parts with CLP (operator s manual) Use brush to clean knurled surface of door assembly

2-65.1/(2-65.2 blank) Change 3

NOTE

M16A2 buttstocks, PN 9349121, with unauthorized markings may be used under the following conditions:

a.

The only authorized markings are those which are temporary In nature, i e , paint, tape, etc

b.

When marking a buttstock, only use temporary markings

c.

Buttstocks with unauthorized markings that have been stamped into the surface of the buttstock will not be used

d.

Unauthorized markings that have previously been scratched, etched, carved, etc may continue In use if the marks do not extend Into the fiber of the buttstock Cutting Into the fiber of the buttstock may weaken it

e.

These marks may be at any location on the buttstock Unauthorized markings are not desirable. However, if previously applied, they will be allowed to continue In use due to the cost of the buttstock.

1. Inspect buttstock for cracks using the following guidelines:

a.

Under the following conditions, hairline cracks (no chipped away material allowed) originating from buttplate end of buttstock are acceptable.

(1)

One hairline crack, not to exceed 1 in. 12.54 cm) In length, per side of buttstock.

(2)

Two additional hairline cracks up to 0 25 in (0 64 cm) In length, per side of buttstock

(3)

A total of three cracks per side of buttstock, originating from buttplate end, are allowable.

b.

Cracks In the critical area at the front end of the buttstock are not acceptable and these buttstocks must be replaced.

1. While buttplate Is Installed on rifle, Inspect for cracks around the mounting holes Check for cracks In excess of 0 25 In. (O 64 cm) In length which extend through the buttplate Replace If cracked.

2. Inspect door assembly for cracks, corrosion, stuck plunger, separations on outer face, or other damage Replace If defective.

Change 3 2-67

2-67.1/(2-67.2 blank) Change 3

a.

Reassembly c. Stowage

b.

Inspection

b. INSPECTION

Perform the following function checks on assembled weapon:

1. Remove magazine if installed. Pull charging handle assembly to rear. Check that chamber is clear. Let bolt and bolt carrier close. Do not pull trigger. Leave hammer in cocked position.

WARNING

If rifle fails any of the following tests, continued use of the rifle could result in injury to, or death of, personnel.

1. Place selector lever in SAFE position and pull trigger. Hammer should not fall.

2. Place selector lever in SEMI position. Pull trigger. Hammer should fall.

M16A2 and M4 ONLY NOTE

For the purpose of the following check "SLOW" is defined as 1/4 to 1/2 the normal rate of trigger release.

1. Hold trigger to the rear, charge weapon, and release the trigger with a slow, smooth motion, without hesitations or stops, until the trigger is fully forward; an audible click should be heard. Hammer should not fall.

2. Repeat the SEMI position test five times. The weapon must not malfunction during any of these five tests. If the weapon malfunctions during any of these five tests, evacuate rifle to support maintenance for repair.

3. Place selector lever in BURST position. Charge weapon and pull trigger. Hammer should fall.

4. Hold trigger to the rear, pull charging handle assembly to rear and release three times. Release trigger. Hammer should not fall. The burst disconnector should have held the hammer to the rear while the trigger was in the pulled position.

5. Pull trigger. Hammer should fall. This should be the first round of a three round burst.

6. With hammer in forward position, attempt to place the selector lever in the SAFE position. If selector lever can be placed on SAFE, evacuate the weapon to support maintenance.

M4A1 ONLY

1. Place selector lever in AUTO position. Charge weapon and pull trigger. Hammer should fall.

2. Hold trigger to the rear, charge weapon and release trigger. Pull trigger. Hammer should not fall. AUTO sear should have released hammer while holding trigger in the squeezed position before releasing and resqueezing the trigger.

3. With hammer in forward position, attempt to place the selector lever in the SAFE position. If selector lever can be placed on SAFE, evacuate the weapon to support maintenance.

Change 4 2-69

Prior to stowing the weapon in arms room, perform the following procedures:

NOTE

Weapon passed into arms room issue window should be passed butt first with the bolt locked to the rear.

1. Clear. Refer to operator’s manual.

2. Place selector lever in SEMI position.

3. Pull trigger. Hammer should fall.

4. Close ejection port (dust) cover.

5. Place weapon in rack.

1. M4/M4A1 Carbine Only, use M12 Arms Rack.

1. The M12 arms rack is the correct arms rack in which to store the M4/M4A1 Carbine. The carbine must be stored with buttstock extended. When storing the M4/M4A1 Carbine in the M12 arms rack a mounting bracket, NSN 5340-01-230-3181, (app D, item 23.1) may be used for each M4/M4A1 Carbine being stored. This option is for the convenience of the person who opens and closes the arms rack to store the carbines.

2. To install the mounting bracket on the M12 arms rack, for use with the M4/M4A1 Carbine, install the bracket with the hooks of the bracket facing toward the carbine, so that the lower receiver extension will contact the bent end of the bracket. The bent end of the bracket will hold the carbine upright when the arms rack is opened. The bracket can be turned around when not in use for the carbine to allow storage of the M16A2 rifle.

3. When storing the M4/M4A1 Carbine in the M12 arms rack, an adapter bar (fig E-6, app E), MUST be used for security reasons. To install the adapter bar to the M12 arms rack:

(1) Remove all weapons from the rack and position the rack to gain access to the back.

2-70 Change 4

Change 4 2-71

(5)

Reinsert the adapter bar into position on the arms rack. Using two 3/8 inch x 2 inch machine screws (MS35206315, NSN 5305-00-984-5695) or equivalent, four washers (MS21306-1C, NSN 5310-01-327-9713) or equivalent and two nuts (MS35649-2382, NSN 5310-00-056-3395) or equivalent assemble adapter bar to arms rack and tighten securely. The bolts can be inserted from either the back or the front to meet your requirements. If the rack is placed close to a wall or another rack It is recommended that the bolts be inserted from the back

(6)

Tack weld, braze, or peen the threaded end of the bolt to the nut to prevent easy removal

(7)

Place rack back into position and replace the weapons NOTE

Adapter bar must be removed from arms rack prior to turning in the arms rack to the supply system.

d.

To remove the adapter bar from the arms rack, remove the head of the bolt (or the nut), using a hand held grinder or file to avoid damage to the aluminum arms rack legs. A hammer and cold chisel may be used If no other way to remove the adapter exist

e.

It is recommended that the rail protector NSN 1005-01-394-7677, (app D, item 26.1) be used during storage of the carbines when the carrying handle assembly or some other accessory is not installed on the upper receiver to prevent damage to the mounting surface on the upper receiver.

Section VI. PREPARATION FOR STORAGE OR SHIPMENT

2-20. PREPARATION FOR STORAGE OR SHIPMENT.

a. Packaging of the M16A2 Rifle and the M4/M4A1 Carbine shall be in accordance with the following

ARMY ONLY: Army users shall package the rifle and the carbine in accordance with each respective Packaging Data Sheet (PDS) for shipment or storage which may exceed 90 days The PDS is part of the Army Master Data File Retrieval Microform System (ARMS) Packaging File AIR FORCE ONLY: Air Force users shall package the rifle in accordance with each respective Special Packaging Instruction (SPI) 00-856-6885 for shipment or storage which may exceed 90 days The SPIs are part of the Army Master Data File Retrieval Microform System (ARMS) Packaging File

b. Packaging, if required, for shipping/storage which will not exceed 90 days shall be as follows

(1) Clean in accordance with operator’s manual

2-72 Change 4

(2)

Wrap with MIL-B-121 waterproof material.

(3)

Place in barrier bag MIL-B-117, Type I, Class C, or wrap with MIL-B-121, Type I, Grade A, and seal with tape, PPP-T-76.

(4)

Place one or more of item in minimum size container. Block and brace in accordance with MIL-STD-1186. Cushion the M16 and similar weight items with PPP-C-843, and use PPP-F-320 as filler, to create a tight pack.

(a)

Fiber board containers shall be in accordance with PPP-B-636 and may be Class Domestic. Gross weight and size of material shall determine grade of fiberboard container. PPP-B-640 may also be used.

(b)

Wood containers shall be in accordance with PPP-B-601 or PPP-B-621.

(5)

Equivalent materials may be used.

c.

NSNs are not assigned to all the specified material. If it is necessary to specify an NSN in the TMs, the packing materials will have to be spared and part numbers and NSNs assigned.

d.

The specifications used are:

CHAPTER 3 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS CHAPTER OVERVIEW

This chapter provides information and instructions to keep the weapon in good repair and contains the following sections:

a.

Repair Parts and Special Tools

b.

Direct Support Troubleshooting

c.

Direct Support Maintenance Procedures for the M1 6A2 Rifle and M4/M4A1 Carbine

d.

Preparation for Storage or Shipment

e.

Preembarkation Inspection of Material in Units Slated for Overseas Movement

Section I. REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

3-1. COMMON TOOLS AND EQUIPMENT. For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE) applicable to your unit. Air Force users must maintain the following common tools:

3-2. SPECIAL TOOLS, TMDE, AD SUPPORT EQUIPMENT. Special tools required for direct support maintenance are listed in appendixes B and C. Fabricated tools are listed and illustrated in appendix E.

3-3. REPAIR PARTS. Repair parts are listed and illustrated in appendix C of this manual.

NOTE

Bolt assemblies, and/or barrel assemblies may be interchanged , at the Direct Support Maintenance level, from one rifle to another, under the provisions of the note on page C-3: If these parts are interchanged the rifle must be checked/inspected as depicted on pages 3-17, 3-21, and 3-33. While performing these checks and inspections, pay special attention to the headspace requirements on page 3-47.

Change 4 3-1

Section II. TROUBLESHOOTING

3-4. GENERAL.

a.

This section contains direct support level troubleshooting information for locating and correcting most of the operating troubles which may develop in the M16A2 rifle and M4/M4A1 carbine. Each malfunction for the individual part or assembly is followed by a list of tests or inspections which will help you to determine the corrective action to take. You should perform the tests/inspections and corrective actions in the order listed.

b.

This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed or is not corrected by listed corrective actions, see individual repair sections in the maintenance procedures on each major assembly.

3-5. TROUBLESHOOTING PROCEDURES. Refer to troubleshooting table for malfunctions, tests, and corrective actions. The symptom index is provided for a quick reference of the malfunctions covered in the table.

SYMPTOM INDEX

Troubleshooting Procedures

3-2 Change 4

FAILURE TO FEED Step 1 Magazine catch spring (1) weak or broken. Replace magazine catch spring I1) (p 3-62)

Step 2 Short recoil Refer to page 3-9 3 FAILURE TO CHAMBER Short recoil. Refer to page 3-9.

3-3

ARMY TM 9 1005 319-23&P AIR FORCE TO 11W3-5 5 42

3-5. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

4. FAILURE TO LOCK. Step 1. Damaged bolt carrier key (1).

Repair or replace bolt carrier key (1) (p 3-25) Step 2 Loose screws (2) on bolt carrier key (1).

a.

Disassemble and repair (p 3-25)

b.

Reassemble using new screws.

Step 3 Bent gas tube (3). a Adjust by bending gas tube 13) In area of handguards b Replace gas tube (3) and check alignment (p 3-29)

Step 4. Short recoil Refer to page 3 9

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

5. FAILURE TO FIRE. Step 1. Broken hammer (1). Replace hammer (1) (p 3-73). Step 2. Weak or broken hammer spring (2). Replace hammer spring (2) (p 3-73). Step 3. Hammer spring (2) improperly assembled. Assemble properly.

Step 4. (M16A2 and M4 ONLY) Burst cam (3) and/or cam spring (4) frozen or improperly assembled

Change 4 3-5’

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

3-5. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

6. FAILURE TO UNLOCK. Step 1

Step 2Step 3.

Burred locking lugs (1) on bolt assembly. Remove burrs. Burred lugs (2) on barrel extension. Remove burrs. Short recoil. Refer to page 3-9.

ARMY TM 9-1005-319-23&P AIR FORCE TO 11 W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

9. FAILURE TO COCK. Step 1. Worn or broken trigger nose (1) or trigger spring (2). Replace trigger (3) or defective trigger spring (2) (p 3-62). Step 2. Worn or broken hammer trigger notch (4). Replace hammer (5) (p 3-62). Step 3. Worn or broken hammer disconnector hook (6). Replace hammer (5) (p 3-62).

Step 4. Worn or broken hammer automatic sear hook (7). Replace hammer (5) (p 3-62).

M16A2 and M4 ONLY M4A1 ONLY

Change 4 3-7

ARMY TM 9-1005-319-23&P AIR FORCE TO 11 W3-5-5-42

3-5. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

Step 5 (M4A1 has only 1 disconnector) Worn or broken disconnector hooks (8). Replace defective disconnectors (9) (p3-62). Step 6 (M4A1 has only 1 spring) Weak, broken, or missing disconnector springs (10). Replace disconnector springs (10) (p 3-62). Step 7. Worn, broken, or missing automatic sear (11). Replace automatic sear (11) (p 3-62). Step 8 Weak or broken automatic sear spring (12). Replace automatic sear (11) (p 3-62). Step 9. Long leg (13) of automatic sear spring incorrectly assembled in receiver. Remove automatic sear assembly (11) and install correctly (p 3-62).

Step 10. (M16A2 and M4 ONLY) Burst cam (14) or clutch spring (15) frozen or improperly assembled. Disassemble, inspect, clean, lubricate, or replace as required (p 3-73).

3-8 Change 4

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

10. SHORT RECOIL. Step 1. Improper gap space or worn, missing, or broken bolt rings (1).

a.

Stagger bolt ring gaps (p 3-21).

b.

Replace bolt rings (1) and stagger gaps (p 3-21).

Step 2. Broken or bent gas tube (2). Adjust by bending in area of handguards or replace gas tube (2)

ARMY TM 9-1005-319-23&P AIR FORCE TO 1 1W3-5-5-42

3-5. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

10 SHORT RECOIL (CONT).

WARNING

When using carbon removing compound (Item 8, app D), avoid skin contact. If it comes in contact with the skin, wash off thoroughly with running water. The use of a good lanolin base cream after exposure to compound Is helpful. The use of gloves and protective equipment Is required. Step 5. Carbon build-up in barrel gas port (5). Remove carbon build-up by soaking barrel In carbon removing compound (item 8, app D). Use rubber gloves (Item 18, app D) with carbon removing compound. Use a bore small arms cleaning brush (Item 4, app D).

11. RIFLE CANNOT BE ZEROED. Step 1 Inspect for defective or bent barrel assembly (1) (p 3-29). Replace barrel assembly (1) (p 3-29).

Step 2 (For windage) barrel assembly (1) out of alignment with rear sight on up per receiver. Align barrel assembly (1) and upper receiver (p 3-291

ARMY TM 9-1005-319-23&P AIR FORCE TO 1 l1W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

Step 3. (For elevation) defective front sight (2) or rear sight (3). Repair as required (p 3-48).

12. FAILURE TO CYCLE WITH SELECTOR LEVER SET ON BURST (M16A2 and M4 ONLY). Step 1. Broken automatic sear (1) or spring (2). Replace automatic sear assembly (1) (p 3-62). Step 2. Faulty selector lever (3). Replace selector lever (3) (p 3-62).

Step 3. Broken tooth on burst cam (4). Replace burst cam (4) (p 3-73).

Change 4 3-11

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

3-5. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

12 FAILURE TO CYCLE WITH SELECTOR LEVER SET ON BURST (M16A2 and M4 ONLY) (CONT). Step 4 Broken cam clutch spring (5) Cam clutch spring should be bent and properly formed without any sharp edges or corners Inspect and replace If required.

Step 5 The bend In the cam clutch spring (5) installed backwards (toward outside). Install cam clutch spring (5) properly with the bend to the inside (p 3-73).

NOTE

When hammer Is rotated back to cocked position, cam should rotate to allow the burst disconnector to latch in the next notch.

Step 6. Cam clutch spring (5) fails to "clutch" and burst cam (4) fails to rotate back with hammer (6). Replace cam clutch spring (5) (p 3-73). If problem continues, replace hammer (6) and cam (4) (p 3-73).

Step 7. Broken front hook (7) on burst disconnector (8). Replace burst disconnector (8) (p 3-62).

Step 8. Short recoil. Refer to page 3-9

3-12 Change 4

ARMY TM 9-1005-319-23&P AIR FORCE TO 1 1W3-5-5-42

TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

12.1. FAILURE TO CYCLE WITH SELECTOR LEVER SET ON AUTO (M4A1 ONLY)

Step 1. Broken automatic sear (1) or spring (2). Replace automatic sear assembly (1).

Step 2. Faulty selector lever (3). Replace selector lever (3).

Step 3. Short recoil. Refer to page 3-9.

13. FIRES TWO ROUNDS WITH ONE PULL OF TRIGGER WITH SELECTOR LEVER SET ON SEMI (DOUBLE FIRING).

Step 1. Defective semiautomatic disconnector (1). Replace semiautomatic disconnector (1) (p 362).

Step 2 Worn or broken trigger notch (2) of hammer (3) (searing portion). Replace hammer (3) (p 3-62).

Step 3. Worn or broken disconnector notch (4) of hammer (3). Replace hammer (3) (p 3-62).

M16A2 and M4 M4A1

Change 4 3-12.1

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

3-5. TROUBLESHOOTING PROCEDURES (CONT). TROUBLESHOOTING (CONT)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

13 FIRES TWO ROUNDS WITH ONE PULL OF TRIGGER WITH SELECTOR LEVER SET ON SEMI (DOUBLE FIRING) (CONT).

Step 4 Worn or broken trigger (5) (searing portion). Replace trigger (5) (p 3-62).

Step 5 Worn trigger or hammer pin hole (6). Gage trigger pin hole (7) and hammer pin hole (6) (p 3-62). If test falls, replace weapon.

3-12.2 Change 4

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

TROUBLESHOOTING (CONT.)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

14. FIRES WITH SELECTOR LEVER ON SAFE OR WHEN TRIGGER IS RELEASED WITH SELECTOR LEVER ON SEMI. Step 1. Defective selector lever (1). Replace selector lever (1) (p 3-62).

Step 2. Worn or broken trigger (rear portion) (2). Replace trigger (3) (p 3-62).

Change 4 3-13

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

3-5. TROUBLESHOOTING PROCEDURES (CONT.). TROUBLESHOOTING (CONT.)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

1. HAMMER PIN "WALKS". Hammer pin (1) "walks" or works loose during firing or hammer pin Is very easy to push out of receiver when hammer Is Installed.

2. Replace hammer assembly (p 3-62).
1. BOLT ASSEMBLY FAILS TO LOCK TO REAR AFTER FIRING LAST ROUND. Step 1. Broken bolt catch (1). Replace bolt catch (1) (p 3 62,. Step 2. Weak or broken bolt catch spring (2). Replace bolt catch spring (2) (p 3-62)

Step 3 Restricted movement of bolt catch (1). Disassemble and clean.

Section III. MAINTENANCE PROCEDURES FOR THE M16A2 RIFLE AND M4/M4A1 CARBINES

Change 4 3-15

3-16

c. INSPECTION

3-18

This page is blank. Procedures and figure were moved to page 2-36.

Change 4 3-19

Replace all authorized unserviceable items. Retest all replaced parts.

1. Visually Inspect bolt rings for cracks, kinks, and bends. Replace all three bolt rings if one or more bolt rings is damaged. See page 3-16 for bolt ring wear check.

3-22

3-23

3-24

3-9. KEY AND BOLT CARRIER ASSEMBLY. b. REPAIR

NOTE

Do not retorque carrier and key screws if staking marks do not indicate loosening screws. Repair by replacing, torquing, and restaking carrier and key screws. Refer to the following reassembly procedures.

3-26 Change 5

c. REASSEMBLY

3-28

Change 5 3-29

2. Slide gas tube (3) back into upper receiver assembly (4) to clear front sight assembly (2). Then lift slightly, pull forward, and remove gas tube (3).

3-30

3-31

3-32

b. INSPECTION/CLEANING

WARNING

When using carbon removing compound, avoid skin contact. If carbon removing compound comes In contact with the skin, wash thoroughly with running water. Using a good lanolin base cream after exposure to compound is help ful. Using gloves and protective equipment is required.

1. Inspect gas tube for cracks. Replace if defective

2. Use carbon removing compound to remove carbon deposits from interior and exterior of gas tube. If a large amount of carbon is found and cannot be removed, replace the gas tube

NOTE

A small arms cleaning brush (bore) (item 4, app D) may be used to clean Interior of front sight assembly where gas tube is secured.

3-34

1. Inspect upper receiver assembly for cracks, corrosion, wear, or damage

1. Small dents or gouges that do not affect functioning will not be cause for rejection.

2. If upper receiver assembly contains cracks or holes, the upper receiver assembly will be replaced

1. Inspect all parts for damage and wear. Replace all defective parts.

NOTE

Damaged or missing teeth of the barrel nut is not cause for rejection provided the proper torque value can be obtained during installation using the tools depicted. If removal of the barrel is not possible with the combination tool, a pipe wrench or other such tool may be used during removal.

8. Inspect front sight guards for bends, if bent see page 3-37 for repair procedures.

c. REPAIR

Change 1 3-35

3-36

3-37

CAUTION

Do not allow solid film lubricant to flow into front sight post threaded well.

(e)

Apply solid film lubricant to cover the damaged finish.

(f)

If front sight guards cannot be straightened utilizing the above procedures, reduce the rifle barrel assembly.

7. Slightly bent barrels may be straightened as follows’.

(a)

Check straightness using straightness gage 8448202 (p 3 45) If the barrel falls the straightness test, and the gage remains in the barrel In the area of the front sight assembly, perform step (b) to determine If it may be straightened.

(b)

With the gage remaining in the bore, hold the rifle in a vertical position with the end of the barrel into which the gage was inserted pointing up Ensure that if when the gage passes through the barrel it will not be damaged Using hand pressure’ ONLY, flex the portion of the barrel between the front sight assembly and the compensator in all four directions (left, right, forward, and back) If the barrel is only slightly bent, the gage will drop through when the barrel is flexed in one of these directions Note the direction which allowed the gage to drop through the’ barrel.

CAUTION

Remove the gage from the barrel before continuing

NOTE

If the gage does not pass through the barrel when it is flexed, replace the rifle barrel assembly.

(c) Place the barrel in a vise using appropriate protective laws . Clamp the barrel between the front sight assembly and the compensator approximately 1 inch (2.54 cm) from the front sight assembly The rifle barrel assembly should be in a horizontal position with the side noted in step (b) toward you.

CAUTION

Do not apply pressure to the receiver.

(d)

Grasp the BARREL near the receiver so that when force is applied the barrel will flex In the same direction as noted In step (b).

(e)

Give the barrel a sharp jerk of approximately 20 to 40 pounds of force (f) Remove the barrel from the vise and recheck straightness (step (al).

(g)

If gage still will not pass through the barrel, perform step (b) to determine direction of bend If the barrel is still bent in the same direction as before, perform steps (c) through (f) using slightly more force. If the barrel Is now bent In the opposite direction, replace the rifle barrel assembly.

(h)

If the gage passes freely through the barrel, the barrel shall be considered straight and continue In service.

(i)

If the barrel has been straightened, the rifle must be targeted (p 3-45).

d. REASSEMBLY

3-40 Change 4

3-41

3-42

CAUTION

NOTE

Do not attempt to hold the upper receiver assembly with a pry bar, however, If the rifle barrel assembly turns In the holding fixture, a pry bar may be used through the front sight assembly base to help prevent the rifle barrel assembly from turning In the holding fixture. Use care not to distort or bend front sight assembly or retaining pins. Use "buddy system" to hold pry bar.

12. Torque the barrel nut assembly again to 30 ft-lb (40.5 N-m) while maintaining sight alignment. The barrel nut assembly may be tightened beyond 30 ft-lb (40.5 N-m) to align the barrel nut assembly serrations for proper gas tube clearance Never loosen the barrel nut assembly to align for gas tube clearance.

NOTE

The peel washer may be heated to remove thin sections. Always place thin section to rear.

14. Install peel washer (11) and compensator (12) on rifle barrel assembly (2).

3-44 Change 4

e. TEST

1. The following information pertains to the use of breech, bore, and other gages:

(a)

All M1 6A2 barrels and chambers are chromed.

(b)

Barrel erosion gage, PN 8448496 (normally used on M16A1 fully-chromed barrels), can be used to gage M16A2 barrels.

(c)

The bore straightness gage, PN 8448202, is required for use on all barrels. The gage must pass through the barrel without being forced.

Change 5 3-45

3-46

Change 4 3-47

3-48

3-49

3-50

b. INSPECTION

Lubricate upper receiver assembly and rear sight assembly. Apply CLP to helical springs and ball bearings (three each) and threaded portion of screws before installation. Lubricate helical springs and ball bearings through their respective drain holes.

3-54

Change 4 3-55

3-56

Change 5 3-58

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

3-12. FORWARD ASSIST ASSEMBLY.

1. Repair forward assist pawl using fine files or stones, as required, to smooth burrs. Do not deform forward assist pawl.

2. Repair pawl detent using fine files or stones, as required, to smooth burrs. Do not deform pawl detent.

3. Repair plunger assembly using fine files or stones, as required, to smooth burrs. Do not deform plunger assembly.

3-60 Change 5

3-61

This task covers:

a.

Disassembly c. Repair e. Reassembly

b.

Inspection d. Test

INITIAL SETUP

Test Equipment Lubricant, solid film (item 21, app D) Tool and Gage Set (item 2, app B) Screw, self-locking (item 6, p C-11 )

Tools Equipment Conditions (ARMY) Small Arms Repairman Tool Kit 3-15 Lower receiver and buttstock assembly (item 3, app B) removed Field Maintenance Basic Less Power 2-57 Buttstock assembly and pistol grip

Small Arms Shop Set (item 1, app B) removed Pivot pin removal tool (fig E-3, app E) Slave pin (fig E-5, app E) General Safety Instructions

To avoid injury to your eyes, use care when Materials/Parts removing and installing spring-loaded parts. Cleaner, lubricant, and preservative (CLP) When using solid film lubricant or dichloro (item 9, app D) methane, be sure the area is well ventilated. Dichloromehtane, technical (item 15, app D)

a. DISASSEMBLY

WARNING

To avoid injury to your eyes, use care when removing and installing spring-loaded parts.

3-62 Change 5

3-63

3-64

Change 4 3-65

3-66

WARNING

When using solid film lubricant or dichloromethane, be sure the area is well ventilated.

CAUTION

Do not use a wire brush on aluminum surfaces.

NOTE

If a weapons lower receiver is missing one third or more of its exterior protective finish, resulting in an unprotected, light reflecting surface, it is candidate for overhaul. This missing finish will be considered a shortcoming. This shortcoming requires action to obtain a replacement weapon. Once a replacement has been received, evacuate the original weapon to depot for overhaul.

Solid Film Lubricant (SFL) is the only authorized touchup for the weapon and may be used on up to one third of the exterior finish of the weapon. FOR ARMY CONUS USE ONLY AND AIR FORCE TRAINING WEAPONS ONLY: SFL may be used as a touchup without limitation on the upper receiver and barrel assembly. This is to say that units which DO NOT fall under the category of Divisional Combat Units or rapid deployment type units may have up to 100 percent of the exterior surface of the upper receiver and barrel assembly protected with SFL if necessary.

c. REPAIR

Repair or replace all parts of lower receiver and buttstock assembly if defective.

Change 4 3-67

3-13. LOWER RECEIVER AND BUTTSTOCK ASSEMBLY (CONT).

1. With the upper receiver attached to the lower receiver, and the pivot pin and takedown pins in place, perform the following test:

1. Apply hand pressure to push the upper receiver as far to one side as possible.

2. Attempt to insert a 0.020 inch thickness gage between the pivot pin lugs of the upper and lower receivers.

3. If the thickness gage penetrates to the pivot pin at all accessible locations, repair by replacement of the upper receiver (see (b) below) or replacement of rifle is required.

1. If the rifle fails the above test, remove the upper receiver and install a "NEW" upper receiver and perform the test again.

2. If the rifle now passes the above test, it shall be considered serviceable and continue in use.

3. If the rifle falls the test with a new upper receiver, this failure shall be considered a shortcoming. This shortcoming requires action to obtain a replacement rifle. Once a replacement has been received, evacuate the original rifle to depot for overhaul.

Change 1 3-69

e. REASSEMBLY

1. Assemble semiautomatic disconnector (1), burst disconnector (2), and trigger assembly (3). Install as a unit in lower receiver (4) using slave pin (5).

2. Install trigger pin (6) using drive pin punch. Push in until flush. Push out slave pin (5).

M4A1 ONLY

1. Install trigger assembly (6.1), disconnector spring (6.2) and disconnector (6.3) into lower receiver and extension subassembly (6.4).

2. Install trigger pin (6.5) using drive pin punch. Push in until flush.

3-70 Change 4

Change 4 3-70.1/(3-70.2 blank) 3-71

11. Install fabricated pivot pin installation tool (19). Insert helical spring (20) and pivot pin detent 21). Compress pivot pin detent in recess with punch and rotate tool. Remove punch.

Change 4 3-73

1. Inspect hammer spring for deformities, breaks, and bends. Pay special attention to the large coil. Replace hammer spring if defective.

2. Inspect cam clutch spring and burst cam for deformities, breaks, and bends; replace if defective.

3. Inspect hammer and hammer pin retainer assembly for chips and breaks. Hammer pin should click home under strong finger pressure. Install hammer pin into hole in hammer to check spring retention of the hammer pin. Replace hammer and hammer pin retainer assembly if defective.

3-74 Change 4

Change 4 3-75

1. Inspect trigger spring for kinks, deformities, and weakness. Replace if defective.

2. Inspect disconnector springs for deformities, bends, breaks, and weakness. Replace if defective.

3. Inspect trigger for chips, wear, and cracks. Inspect for damaged searing surface on the trigger nose. Replace if defective.

c. REASSEMBLY

M16A2 AND M4 ONLY NOTE

Use bolt carrier key tool to install disconnector springs.

1. Use the following procedures to install two disconnector springs (1) using the bolt carrier key tool:

(a)

Secure the trigger (2) in a soft vise jaws or similar device.

(b)

Place one spring (1) firmly on the tool with large diameter coils outward.

(c)

Press spring (1) into recess to solid height.

(d)

Hold spring at solid height and slide spring into one of the holes until the punch is flush and perpendicular with the recess

wall.

(e)

Turn the spring one to two turns opposite of coil winding of the spring.

(f)

Discontinue winding when an audible click or snap is heard or felt. This indicates that the spring is seated.

(g)

Hold the spring (1) in place when removing

the tool to avoid unseating or damaging the spring.

M4 CARBINE ONLY NOTE

The semi and burst disconnector springs are not the same. The Semi disconnector spring (left side) (figure C-15, item 1B) is black while the burst disconnector spring (right side) (figure C-15, item 1A) is nickel (shiny). Ensure that the correct spring is installed on each side for proper functioning.

3-76 Change 4

Change 4 3-76.1/(3-76.2 blank)

ARMY TM 9-1005-319-23&P AIR FORCE TO 11W3-5-5-42

3-16. LOWER RECEIVER AND RECEIVER EXTENSION ASSEMBLY.

3-16. LOWER RECEIVER AND RECEIVER EXTENSION ASSEMBLY (CONT).

a. DISASSEMBLY (CONT)

3. Use padding between lower receiver and brass vise laws. Grip the solid portion of the lower receiver with brass vise jaws which conform to the shape of the lower receiver in this area.

RIFLE ONLY

4. Clamp lower receiver (2) in a machinist’s vise using vise jaw caps and tighten on solid portion just tight enough to hold.

WARNING