AR Upper Troubleshooting

Utilize these steps after following all the Lower Troubleshooting steps.

• Issue: The charging handle or bolt carrier group “binds” or “sticks” about ¾ of the way to the rear.
  • Solution 1 (Super Safety Specific): The rear shelf of the upper needs to be cut to prevent the lever from being pinched between it and the BCG (Bolt Carrier Group). Please see Pictures 2 and 3 below for before and after examples of the shelf cut. You may use a Dremel to quickly remove this.
  • Solution 2: This solution should not be needed if the aforementioned upper cut is performed, we do not recommend this solution in 99% of installations. The flat “top” of the lever is too tall and needs to be ground down some to prevent binding between the BCG and cam. If it is still necessary, use a Dremel with a drum sander (40-80 grit) to grind the top of the lever some until it functions smoothly. Note: We will not cover any failures of the lever resulting from this modification.
  • Solution 3: If the bolt is over-traveling too far into the buffer tube, you either need a longer buffer (rifle length buffer) or you may place 1-4 quarters in the rear of the buffer tube behind the spring to “shorten” the tube (not our recommended solution, but it has worked).

• Issue: The trigger is “dead” or “locked” after one round during dry fire or live fire. It acts like it’s in the safe position.
  • Solution: Verify you are using a Full Auto BCG. Some manufacturers such as S&W or Ruger use a Semi Auto BCG which lacks the rear of the opening to actuate the lever back forward, so you will feel the reset as it goes back, but it will be left locked up. See Picture 4 below for examples of what a Full Auto BCG looks like.

• Issue: The bolt on my PCC (AR-9 or similar) won’t close fully into battery.
  • Solution: You need to cut the bolt weight or replace it with one that sits flush in the opening. See Picture 5 below for an example of the bolt weight cut.

Picture 2 – Upper shelf before cut

Picture 3 – Upper shelf after cut

(note it goes back completely)

Picture 4 – Full Auto BCG vs Semi-Auto BCG

(note length of bottom opening)

Picture 5 – AR PCC Bolt Weight Cut

(note that the height has been reduced, we recommend halfway through the height of the bolt or all the way through completely)