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Full text of "Army Technical Manual (for M16 rifle) - TM9-1005-249-23P"

COAST 



ARMY TM Q-innf>-94Q-9.q&P 

AIR FORCE TO 11W3-5-5-24 
GUARD COMDTINST M8370.9 

Supersedes Copy Dated November 1983 
TECHNICAL MANUAL 



UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL 
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) 

RIFLE, 5.56MM, M16 (1005-00-856-6885) (EIC:4F7) 
RIFLE, 5.56 MM, M16A1 (1005-00-073-9421) (EIC:4FC) 



INTRODUCTION M 




DISTRIBUTION STATEMENT. Approved for public 
release; distribution is unlimited. 

HEADQUARTERS, DEPARTMENTS OF THE ARMY AND) 
AIR FORCE, COMMANDANT, COAST GUARD 



UNIT MAINTENANCE INSTRUCTIONS 2-1 



DIRECT SUPPORT 
MAINTENANCE INSTRUCTIONS 



3-1 




MAINTENANCE AUXILIARY 
EQUIPMENT 


4-1 


JjM 






1 


REFERENCES 


A-1 


HH 








1 MAINTENANCE ALLOCATION CHART 


B-1 


IJB^ 








REPAIR PARTS AND SPECIAL 
TOOLS LIST 


C-1 


Hi 






1 


EXPENDABLE/DURABLE SUPPLIES AND 
MATERIALS LIST 


D-1 


f/M 






_^^ J 


ILLUSTRATED LIST OF 
MANUFACTURED ITEMS 


E-1 


m 






1 


TORQUE LIMITS 


F-1 


HH 






1 


1 ALPHABETICAL INDEX 


INDEX-1 


■■ 



JUNE 1991 



METRIC CHART 

THE METRIC SYSTEM AND EQUIVALENTS 



LINEAR MEASURE 



1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 
1 Kilometer = 1000 Meters = 0,621 Miles 

WEIGHTS 

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 

1 Kilogram = 1000 Grams = 2.2 Lb 

1 Metric Ton = 1000 Kilograms = 1 Megagram =^1.1 Short Tons 

LIQUID MEASURE 

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 



SQUARE MEASURE 

1 Sq Centimeter = 100 Sq Miliimeters = 0.155 Sq Inches 
1 Sq Meter = 10,000 Sq Centimeters - 10.76 Sq Feet 
1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Mtles 

CUBIC MEASURE 

1 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches 
1 Cu Meter = 1,000,000 Cu Centimeters - 35,31 Cu Feet 

TEMPERATURE 

5/9 (°F -321 = °C 

212° Fahrenheit is equivalent to 100° Celsius 

90° Fahrenheit is equivalent to 32.2° Celsius 

32° Fahrenheit is equivalent to 0° Celsius 

9/5 C° +32- F° 



TO CHANGE 



TO 



APPROXIMATE CONVERSION FACTORS 
MULTIPLY BY 



Inches Centimeters 2.540 

Feet Meters 0.305 

Yards Meters 0.914 

Miles Kilometers 1 .609 

Square Inches Square Centimeters 6.451 

Square Feet Square Meters 0.093 

Square Yards Square Meters 0.836 

Square Miles Square Kilometers 2.590 

Acres Square Hectometers 0.405 

Cubic Feet Cubic Meters 0.028 

Cubic Yards Cubic Meters 0.765 

Fluid Ounces Milliliters 29.573 

Pints Liters 0,473 

Quarts Liters 0.946 

Gallons Liters 3,785 

Ounces Grams 28.349 

Pounds Kilograms 0.454 

Short Tons Metric Tons 0.907 

Pound-Feet Newton-Meters 1.356 

Pounds per Square Inch . . Kilopascals 6.895 

Miles per Gallon Kilometers per Liter 0.425 

Miles per Hour Kilometers per Hour 509 



TO CHANGE 



TO 



MULTIPLY BY 



Centimeters Inches 0.394 

Meters Feet 3.280 

Meters Yards 1 .094 

Kilometers Miles 0.621 

Square Centimeters Square Inches 0. 1 55 

Square Meters Square Feet 10.764 

Square Meters Square Yards 1.196 

Square Kilometers Square Miles 0.386 

Square Hectometers Acres 2.471 

Cubic Meters Cubic Feet 35.31 5 

Cubic Meters Cubic Yards 1.308 

Milliliters Fluid Ounces 0.034 

Liters Pints 2.113 

Liters Quarts 1.057 

Liters Gallons 0.264 

Grams Ounces 0.035 

Kilograms Pounds 2.205 

Metric Tons Short Tons 1.102 

Newton-Meters Pound-Feet 0.738 

Kilopascals Pounds per Square Inch 0. 1 45 

Kilometers per Liter Miles per Gallon 2.354 

Kilometers per Hour Miles per Hour 0.621 



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ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



WARNING 



RADIATION HAZARD 



K^ 



TRITIUM (H3) 

A. RULES AND REGULATIONS: Copies of the following rules and regulations are maintained at HQ, AMCCOM, 
Rock Island, IL 61299-6000. Copies may be requested, or information pertinent to these rules and regulations 
obtained, by contacting the AMCCOM Radiological Protection Officer (RPO), AUTOVON 793-2964/2965/2966 
Commercial (309) 782-2964/2965/2966. 

(1 ) 1 0CFR Part 1 9 - Notices, Instructions, and Reports to Workers; Inspections. 

(2) 10CFR Part 20 - Standards for Protection Against Radiation. 

(3) NRC license, license conditions, and license application. 

B. SAFETY PRECAUTIONS. The radioactive material used in this rifle is tritium gas (H3) sealed in a glass tube. It 
poses no significant hazard to the repairman when intact. The source illuminates the front sight for night opera- 
tions. Tampering with or removal of the source in the field is prohibited by Federal law. In the event there is no 
illumination, notify the local Radiological Protection Officer. Do not attempt to repair or replace the sight in the 
field! If skin contact is made with any area contaminated with tritium, immediately wash with nonabrasive soap 
and water. 

C. IDENTIFICATION: The radioactive self-luminous source is identified by means of a radioactive warning label {as 
above). This label should not be defaced or removed, and should be replaced immediately when necessary. 
Refer to the local RPO or the AMCCOM RPO for instructions on handling, storage, or disposal. 

D. STORAGE AND SHIPPING: All radioactively illuminated instruments or modules which are defective will be 
evacuated to a depot maintenance activity. These items must be placed in a plastic bag and packaged in the 
shipping container from which the replacement was taken, before evacuation to a higher echelon is made. Spare 
equipment must be stored in the shipping container, as received, until installed on the weapon. Storage of these 
items is recommended to be in an outdoor shed type storage or unoccupied building. 



WARNING 

Read this manual carefully before performing required maintenance. This manual will be referred to for Inspection/ 
Maintenance and Repair procedures. 

Before starting an inspection, be sure to clear the rifle. Do not actuate the trigger until the rifle has been cleared. In- 
spect the chamber to ensure that it is empty and no ammunition is in position to be chambered. Do not keep live am- 
munition near work area. 

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

All Active Army M161/M16A1 rifles must be inspected and gaged at least once annually for safety. All Army Reserve 
and Army National Guard M16/M16A1 rifles must be inspected and gaged at least once every two years, after the in- 
itial inspection/gaging procedures have been accomplished. This two year interval may be maintained unless preven- 
tive maintenance checks and services (PMCS), or other physical evidence indicates that an individual unit's M16/ 
M16A1 rifles require inspection 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. 

Air Force users refer to inspection requirements in AFR 50-36, Volume 1 . 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO-11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

WARNING (cont) 

Below Direct Support Maintenance, DO NOT Interchange bolt assemblies from one weapon to another. Doing so 
may result In Injury to, or death of, personnel. 

Bolt cam pin must be Installed or weapon 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 we 1 1- ventilated area. The use of rubber 
gloves is necessary to protect the skin when washing rifle parts. 

When using solid film lubricant or dichloro methane, be sure the area is well ventilated 

When using P-C-1 1 1 , avoid skin contact. If It comes In contact with the skin, wash off thoroughly with running 
water. Using a good lanolin base cream after exposure to compound is helpful. Gloves and protective equipment 
are recommended. 

For further Information on safety, care, and handling of ammunition: Army and Air Force users refer to 
M16/M16A1 Operator's Manual TM 9-1 005-249-1 0/TO 11A13-10-7; Coast Guard users refer to OP4 or OPS. 

For additional first aid data, see FM 21 -1 1 



TECHNICAL MANUAL 

ARMY NO. 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



*ARMY TM 9-1005-249-23&P 
*AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

HEADQUARTERS, DEPARTMENTS OF THE ARMY 

AND AIR FORCE 
COMMANDANT, COAST GUARD 

Washington, DC 19 June 1991 



Unit and Direct Support Maintenance Manual 
(Including Repair Parts and Special Tools List) 

RIFLE, 5.56MM, M16 

(1005-00-856-6885) 
RIFLE, 5.56MM, M16AI 

(1005-00-073-9421) 

Current as of 7 January 1991 

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), located in the back of this manual direct to: Com- 

mander, US Army Armament, Munitions and Chemical Command, ATTN: AMSMC-MAS, 
Rock Island, IL 61299-6000. 

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

Coast Guard users submit Publications Correction/Change Report form CG 4394 to: Com- 
mandant, U.S. Coast Guard (G-ODO-2), Washington, DC 20593-0001. 

A reply will be furnished to you. 



Page 



HOW TO USE THIS MANUAL. 



I CHAPTER II INTRODUCTION [R] 

Chapter Overview 11-11 

Section I General information |1-1| 

Section II Equipment Description and Data [T?] 

Section III Principles of Operation |T^ 



I CHAPTER 2I UNIT MAINTENANCE INSTRUCTIONS \^ 

Chapter Overview 12-11 

Section I Repair Parts, Special Tools, TMDE, and Support Equipment [2^1 

Section II Service Upon Receipt .[2^ 

Section III Preventive Maintenance Checks and Services (PMCS) J 2-31 

Section IV Troubleshooting 12-121 

Section V Decontamination of Rifles and Arms Rooms \ 2-21 1 

Section VI Maintenance Procedures J 2-211 



*This manual supersedes TM 9-1005-249-24&P, dated 25 November 1983, including all changes and TO 
1 lVtf3-5-5-24 dated 10 February 1972. 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



Page 



ICHAPTER^ 



Section 
Section 
S ectio n 
S ectio n 
Section 
S ection 



DIRECT SUPPORT MAINTENANCE INSTRUCTIONS |3 - 1| 

Chapter Overview ^ 

Repair Parts, Special Tools, TMDE, and Support Equipment E 

Service Upon Receipt E 

Troubleshooting E 



Decontamination of Rifles Shop Area 13-91 

Maintenance Procedures for the Ml 6 and M16A1 Rifle 13-1 01 

Preembarkation Inspection of Materiel in Units Alerted for Overseas 13 - /3| 

Movement 



Illus 
Figure 



[chapter 4 I MAINTENANCE OF AUXILIARY EQUIPMENT JTTI 

Chapter Overview 14-1 1 

Section I Unit Auxiliary Equipment 1 4-11 

S ectio n II Preparation for Storage or Shipment 14-131 



I APPENDIX" 



APPENDIX 



Section 
S ectio n 
I G r u p 



[Group 



Ig rn i] p 



E 



roup 



Section 

Section 



APPFNniy 



XI REFERENCES Pm 



I APPENDIX B I MAINTENANCE ALLOCATION CHART HZ! 



N 

ol 



3 



3 I 



I G r u p 4I 



REPAIR PARTS AND SPECIAL TOOLS LIST E] 

Introduction ID-II 

Repair Parts List U-1-11 

5.56MMRifle M16,8448600 and M16A1, 8448500 1. C-J-ll 

Bolt carrier assembly 8448501 I . . C-2-11 

01 01 Bolt Assembly 8448509 I. . . C-'^-U 

0102 Key and bolt carrier assembly 8448505 1. . tJ-4-11 

Charging handle assembly 844851 7 I 0-5-1I 

Upper receiver and barrel assembly 8448601 {Ml 6) and 

8448522 (Ml 6A1 ) [TeTI 



3] 



0301 Rifle barrel assembly 8448663 1. . G-7-1 1 

0302 Upper receiver assembly 8448602 (M16) and 8448523 (M16A1) RT^ 

030201 Forw/ard assist assembly 9349 086(M16AI) I.C-^-11 

Lower receiver and extension assembly 8448604 (Ml 6} and 

8448578 (Ml 6A1 ) < K-in-1l 

0401 Buttstock assembly 93491 19 I . G-11-11 



0402 Hammer assembly 844861 1. G-1P-1I 

0403 Trigger assembly 8448591 1. . 0-13-11 

0404 Lower receiver and extension subassembly 84488605 (Ml 6) 

and 8448579 (M16A1} J C-14-11 

Special Tools List IC-15-1 1 

National Stock Number and Part Number Index I 1-1 1 

EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST rTvil 



APPENDIX H ILLUSTRATED LIST OF MANUFACTURED ITEMS IFTI 

Iappendix fI torque limits EZU 



IaLPHABETICAL INDExI I ndex 



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14 




15 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



HOW TO USE THIS MANUAL 



Read this manual carefully before performing required maintenance. This manual will be referred to for 
Inspection/Maintenance and Repair procedures. 



GENERAL 



There arc 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. 

2. Illustrations for the maintenance procedures show only those parts affected by the opeation being performed. 

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

4. When the term "evacuate to support maintenance" is used, the entire rifle must be evacuated. 



[NDEXES 

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

1. Front Cove-r Index. Lists the most important areas of the manual. It is keyed to areas with bleed-to-edge indicators. 

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

3. Nomenclature Cross-References List. 

4. Chapter Overviews. Summarise material covered in the chapter. Are located at the beginning of each chapter. 

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

6. 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. 

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 uses the Tool Set, Gage Set 
and/or Shop Set listed in the initial setup. 

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

3. References. Lists other publications containing necessary information, 

4. 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. 

5. General Safety Instructions. Lists safety instructions to follow before performing maintenance procedures. 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



EXTERNAL VIEW OF 5.56MM RIFLE M16 



BUTTSTOCK ASSEMBLY 



LOWER RECEIVER AND 
EXTENSION ASSEMBLY 



UPPER RECEIVER AND 
BARREL ASSEMBLY 




CARTRIDGE 
MAGAZINE 



UPPER RECEIVER AND 

BARREL ASSEMBLY 



SMALL ARMS 

SLING 



BUTTSTOCK ASSEMBLY 




SMALL ARMS 
SLING 



CARTRIDGE 
MAGAZINE 



LEFT SIDE 



LOWER RECEIVER AND 
EXTENSION ASSEMBLY 



RVTFRNAI. VIKW OF 5.SfiMM RIFLE M16A1 



BUTTSTOCK ASSEMBLY 



UPPER RECEIVER AND 
BARREL ASSEMBLY 




LOWER RECEIVER AND 
EXTENSION ASSEMBLY 



SMALL ARMS 
SUNG 



RIGHT SIDE 



SMALL ARMS 
SLING 



UPPER RECEIVER AND 
BARREL ASSEMBLY 



BUTTSTOCK ASSEMBLY 




CARTRIDGE 
MAGAZINE 



LOWER RECEIVER AND 
EXTINStON ASSEMBLY 



LEH SIDE 



1-0 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

CHAPTER 1 
INTRODUCTION 
CHAPTER OVERVIEW 

This chapter contains general information equipment description and data and principles of operation for your weapon. 

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 M 16 and M16A1. 

c. Purpose of Equipment. Provides personnel an offensive/defensive capability to engage targets for field use. 

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 11 W 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 l chapter "4l| paragraph 4-7. | Air Force users refer to Special 
Packaging Instructions (SPI) 00-856-6885. 

1-5. OFFICIAL NOMENCLATURE, NAMES AND DESIGNATIONS. 

NOMENCLATURE CROSS-REFERENCE LIST 

Common Name Official Nomenclature 

ActionSpring Helical Compression Spring (8448629) 

BoltCatch Spring Helical Compression Spring (8448633) 

Carrier Key and Bolt Carrier Assembly (8448505) 

Disconnector Spring Helical Compression Spring (8448594) 

Ejector Spring Helical Spring (8448516) 

Extractor Spring Assembly Spring Assembly (8448755) 

Hammer Spring Helical Torsion Spring (844861 1 ) 

Magazine Catch Spring Helical Compression Spring (8448637) 

Pistoi Grip Rifle Grip (93491 27) 

Pivot Pin Detent Takedown Detent (8448585) 

TriggerSpring Helical Torsion Spring (8448593) 

Weapon 5.56mm Rifle M 16 (8448600) or M 1 6A1 (8448500) 

1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR). If your 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. Put it on SF 368 (Product Quality Deficiency Report). Mail it to us at Com- 
mander, US Army Armament, Munitions and Chemical Command, ATTN: AMSMG-QAD-I, Rock Island, IL 
61299-6000. We'll send you a reply. 

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// lAW Technical Order 00-35D-54. 

Coast Guard users submit PQDRs (SF 368) in accordance with COMDTINST M4855.1 to: Commandant, U.S. Coast 
Guard (G-ODO-2), Washington, DC 20593-0001. 



1-1 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



Section II. EQUIPMENT DESCRIPTION AND DATA 
1-7. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES. 
a. Characteristics. 



(4) Magazine-fed 

(5) Semi or automatic fire 



(1) Lightweight 

(2) Air-cooled 

(3) Gas-operated 

b. Capabilities. Provides personnel an offensive/defensive capability to engage targets while in the field role. 

c. Features. 



(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 weapon. The bolt and barrel extension con- 
tains locking lugs which engage and lock the bolt firmly in the barrel extension. The initial force of the explosion of 
the cartridge propellant is absorbed by the barrel, barrel extension, and bolt. 

(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 cover must be closed 
during periods when firing is not anticipated. It opens automatically by the forward or rearward movement of the bolt 
carrier. 

1-8. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS. 





® 



® 



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

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

UPPER RECEIVER AND BARREL ASSEMBLY. Rifle barrel assembly Is air-cooled, contains flash suppressor and 
front sight assembly, and holds the two hand guards and the sling swivel. Upper receiver contains 
rear sight, ejection port and cover, and a housing for the bolt carrier and bolt assembly. A forward 
assist assembly is used on the Ml 6A1 weapon. 

LOWER RECEIVER AND EXTENSION 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. 

CARTRIDGE MAGAZINE. 30 round cartridge capacity. 

SMALL ARMS SLING. The small arms sling is adjustable and provides a means to carry the weapon. 

A 




1-2 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

1-9. DIFFERENCES BETWEEN MODELS. The 5.56mm Rifle M16 does not contain the forward assist assembly con- 
tained on 5.56mm Rifle M16A1. 

1-10. EQUIPMENT DATA. 

a. Rifles and M16 and M16A1. 

Weight: 

Rifle M16, without magazine and Sling 6,351b 

Rifle Ml 6A1 , without magazine and sling 6.5.5 lb 

Sling M1 , , ,.,..,.,,.,,.,.., , , 0.41b 

Empty magazine 0.251b 

Loaded magazine 1 .01 lb 

Rifle Ml 6, w/sling and loaded magazine 7.76 lb 

Rifle Ml 6A1 w/sling and loaded magazine 7.96, lb 

Bayonet-Knife M7 , 0.61b 

Scabbard M10 0.31b 

Length: 

Rifle w/flash suppressor 39.625 in. 

Rifle w/bayonet-knife 44.875 in. 

Barrel 20in. 

Barrel with flash suppressor 21 in. 

Mechanical features: 

Rifling - RH twist, 6 grooves, 1 turn in 1 2 inches 

Method of operation gas 

Typeof breech mechanism rotatlngbolt 

Method of feeding magazine 

Cooling air 

Trigger pull 5.5 to 8.5 lb 

Ammunition: 

Caliber , , 5.56 mm 

Type ball, blank, dummy and tracer 

Firing characteristics: 

Muzzle velocity (approximate) 3,250 fps 

Muzzle energy 1,,3,00, .ft-lb 

Chamber pressure 52,000 psi 

Cyclic rate of fire (approximate) 800 rds/m 

Maximum rate of fire: 

Semiautomatic 45/65 rds/m 

Automatic 1 50/200 rds/m 

Sustained rate of fire 12/15 rds/m 

Maximum range 2.,653 meters 

Maximum effective range. 460 meters 

b. Rifle Bipod M3. 

Weight: 

Bipod , , . , ,..,., ,.,.., , ,.,.., o.6lb 

Bipod case 0,21b 



1-3 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



Section 



PRINCIPLES OF OPERATION 



1-11. GENERAL. The 5.56mm Ml 6/IV11 6A1 rifle: 

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

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



1-12. PRINCIPLES OF OPERATION. 



^O BOLT AND CARRIER ASSEMBLY. Provides stripping, cambering, locking, firing, extraction, 
cartridges using the drive springs and projectile propelling gases for power. 



and ejection of 



(b) CHARGING HANDLE ASSEMBLY. Provides initial charging of the weapon. The charging handle latch locks the 

handle in the forward position during sustained fire to prevent injury to the operator. 

(c) UPPER RECEIVER AND BARREL ASSEMBLY. Provides support for the bolt carrier assembly. The barrel 

chambers the cartridge for firing and directs the projectile. 

(^ LOWER RECEIVER AND EXTENSION ASSEMBLY. Provides firing control for the weapon and provides storage 
for basic cleaning materials. 

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

rp^ SMALL ARMS SLING. Provides the means for carrying the weapon. 







M16A1 



1-4 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M837.9 

1-13. 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 the 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. 

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. 

The form should be submitted to: 

Commander 

U.S. Army Armament, Munitions and Chemical Command 
ATTN: AMSCM-QAD/Customer Feedback Center 
Flock Island, Illinois 61299-6000 

Air force users submit Material 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 



1-5 (1-6 blank) 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

CHAPTER 2 
UNIT MAINTENANCE INSTRUCTIONS 
CHAPTER OVERVIEW 

This chapter contains information and instructions to help keep the weapon in good repair. The chapter contains: 

a. Repair Parts, Special Tools, TMDE, and Support Equipment 

b. Service Upon Receipt 

c. Preventive Maintenance Checks and Services (PMCS) 

d. Troubleshooting 

e. Decontamination of Rifles and Arms Rooms 

f. Maintenance Procedures 

Section 1. 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 and Coast Guard users must maintain the 

following common tools: 

Three-ounce soft-brass hammer Tweezers/round nose pliers 

Vise Hammer 

Flat tip screwdriver Needle nose pliers 

Punch 

2-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT. Special tools, required for unit support are liste d in appervl 
dix ^ Fabricated tools are listed and illustrated in l appendix LI 

2-3. REPAIR PARTS. Repair parts are listed and illustrated in lappendix U D f this manual. 

Section II. SERVICE UPON RECEIPT 
2-4, GENERAL. 

a. Inspect the weapon for damage incurred during shipment. If the equipment has been damaged, report the 
damage on SF Form 364, Report of Discrepancy (ROD). 

b. Check the weapon against the packing slip to see if the shipment is complete. Report all discrepancies in accor- 
dance with the instructions in DA PAM 738-750. 

Army users submit an SF 368 (Product Quality Deficiency Report) to: Commander, U.S. Army Armament, Munitions 
and Chemical Command, ATTN: AMSMC-QAD-1, Rock Island, IL 61299-6000. 

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

Coast Guard users submit PQDRs (SF 368) in accordance with COMDTINST M4855.1 to: Commandant, U.S. Coast 
Guard (G-000-2), Washington, DC 20593-0001. 

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

d. Check to see if all MWOs have been applied. 



2-1 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

2-5. SERVICE UPON RECEIPT OF MATERIEL. Refer to the following table. 

WARNING 

Before starting an inspection, be sure to clear the weapon. Do not actuate the trig- 
ger before clearing the weapon. 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 - M16/M16A1 RIFLE 



LOCATION 



ITEM 



ACTION 



REMARKS 



1 . Container 



M16/M16A1 Rifle 



a. Remove rifle from containers. 



b. Inspect the equipment for dam- 
age incurred during shipment. 



If the equipment has 
been damaged, report 
the damage on SF Form 
364, Report of Discrep- 
ancy (ROD), 



c. Check the equipment against the 
packing list to see if the ship- 
ment is complete. 



Report all discrepancies 
in accordance with the 
instructions of DA RAM 
738-750. 



b. Basic issue items 



Check for missinq items. 



ITM 9-1005-249 -10 (Op- 
erators Manual) 



2. Rifle 



a. Barrel assembly 



If volatile corrosion inhibitor (VCI) is 
in barrel, remove and discard. 



b. All parts 



a. Field-strip rifle and inspect for 
missing, damaged, and rusted or 
corroded parts. 



Refer to Operator's 
Manual 



b. Clean and lubricate. 



Refer to Operator's 
Manual 



c. Reassemble. 



Refer to Operator's 
Manual 



d. Function check 

e. Check to see whether the equip- 
ment has been modified. 



Refer t d paragraph 2-^ b 
DA PAM 25-30 



2-2 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

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 weapon. 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 a 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 Mainte- 
nance 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. 

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



2-3 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16/M16A1 RIFLE 



Item 
No. 



Interval 



Item To Be 

Checked Or 

Serviced 



Procedure 



Not Fully Mission 
Capable If; 



WARNJNG 

Before starting an inspection, be sure to clear the rifle. Do not actuate 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. 

NOTE 

During periods of inactivity, perform preventive maintenance quarterly unless 
inspection reveals more frequent servicing is necessary. 

An inactive weapon is a weapon which has been stored in an arms room for a period 
of 90 days without use. The weapon may or may not have been assigned to an 
individual. 



Normal cleaning (PMCS) of an inactive weapon will be performed every 90 days. 
Should the unit armorer detect corrosion on a weapon prior to the end of the 90-day 
period, the PMCS should be performed immediately. 

Solid Film Lubricant (SFL) is the authorized touch up for the M16/M16A1 Rifle and 
may be used on up to one third of the exterior finish of the weapon. 
FOR CONUS USE ONLY: Solid Film Lubricant may be used as a touch up 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% of the exterior surface of the Upper Receiver and Barrel 
Assembly protected with SFL. Prior to application of SFL the surface must be 
thoroughly clean and inspected for corrosion and/or damage. If corroded or 
damaged the part must be repaired or replaced prior to application of SFL. Continued 
use under combat conditions would result in an unprotected surface when the SFL 
wears off. This would result in a large light reflecting surface and accelerated 
deterioration of the unprotected surface. Therefore, Divisional Combat Units and 
units which fall under the definition of Rapid Deployment type must adhere to the 
limitation of NOT over 1/3 of their exterior surface covered by SFL. 



Quarterly 



Cartridge magazine 
(serviceability check) 




a. Disassemble as in operators manual 
Inspect tube (1) for bulges, dents, or 
damaged feeder lips (2). Inspect spring 
nd follower (4) for kinks or damage, 

eassemble magazine and check for 
ng during operation of follower (4). 



SH - Replace the maga- 
zine if any of these con- 
ditions exist. 



SH - Replace the maga- 
zine if the follower 
I binds 



2-4 



ARMYTM 9-1005-249-23&P 

AIR FORCET0 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16/M16A1 RIFLE (Cont) 



Item 
No. 



Interval 



Item To Be 

Checked Or 

serviced 



Procedure 



Not Fully Mission 
Capable If: 



2 (Quarterly Cjiarging handle as 
sembly and selector 
lever. 




WARNING 

If the weapon fails any of the 
following selector lever teats, 
evacuate it to Direct Support 
Maintenance. Continued use of 
the weapon could result in in- 
jury to, or death of, personnel. 

Pull charging handle (1) to rear. Check 
that chamber is clear. Let bolt and bolt 
carrier (2) close. Leave hammer in 
cocked position. Do not pull trigger. 

Place selector lever (3) in SAFE position. 
Pull trigger. Hammer should not fall. 

NOTE 



For the purpose of the follow- 
ing test "SLOW" is defined as 
1/4 to 1/2 the normal rate of 
trigger release. 

Place selector lever (3) in SEMI position. 
Pull trigger. Hammer should fall. 

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.) Ham- 
mer should not fall. 

Repeat the above SEMI position test five 
times. 



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

Hold trigger to the rear, charge weapon, 
and release trigger. Pull trigger. Hammer 
should not fall. 

NOTE 



Automatic sear should have 
released hammer while holding 
trigger in the pulled position 
before releasing and pulling 

the trigger. 

With hammer in forward position, at- 
tempt to place the selector lever (3) in 
SAFE position using finger/thumb pres- 
sure only.. 



D - Charging handle 
must lock in place 
when in the forward 
position. 

D - Hammer falls. 



D - Hammer does not 
fall. 

D - Hammer falls. 



D - The weapon mal- 
functions during any of 
these five tests. 

D - Hammer does not 
fall. 

D - Hammer falls. 



D - Finger/thumb pres- 
sure moves fire control 
selector to SAFE 
position. 



2-5 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16/M16A1 RIFLE (Cont) 







Item To Be 






Item 




Checked Or 




Not Fully Mission 


No. 


Interval 


Serviced 


Procedure 


Capable If: 


3 


Quarterly 


Upper receiver and 
barrel assembly 
(handguards) 


CAUTION 

Do not use screwdriver or any 
other tool when removing the 














handguards, doing so may 














damage the handguard and/or 












^ 


slip ring. 






^^"■"■■' 


^*^T^i 




^r^ 








^^ ^ **^ 


/7N^^ 




^^ 


NOTE 






^r "" ^» 


^^^k. i^i. 










^ 


\ "^ ^ 


^^^7S 






Refer to operator's manual for 




'\ 


\ 




^ 




"buddy system" procedure on 




\ 


y^ 








removing handguards. 




> 












Remove and inspect handguards (1) in- 


SH - Discard and re- 


^ 


t 






n 


ternally and externally for cracks and/or 


place the handguard 




^y^ 






damage. Cracks up to one inch in length 


assembly (1) if the heat- 




j^^^ ^^ 






are acceptable providing they do not ex- 
tend into the handguard retaining flange 


shield is loose enough 
to rattle when installed 


^^ 


v^^ 


^iniih "^ 


■^ 


In y 1 


or adversely affect weapon operation, 


on the rifle or it fails 


\ 




Till W L i\ 


operator safety, or proper retention of 
handguard. 


the inspection. 


4 


Quarterly 


Upper receiver and 
barrel assembly (ser- 
viceability check) 


WARNING 

Dry cleaning solvent is flamma- 
ble and toxic and should be 
used in a well-ventilated area. 
The use of rubber gloves is 








^T 








(T^) *7/ 


necessary to protect the skin 






G 


V ^^ // 


when washing rifle parts. 






^f^-^CLm 


Release takedown pins and open and 


D - If flash support or 






V/ArJ* 


separate receivers Hand check flash sup- 


barrel are loose, evacu- 






^qM^ 


pressor (1) for looseness on barrel (2), 


ate to direct support 




y.r— V 


MTrh. 


then hand check barrel for looseness on 


maintenance. 




© 


Mi \ T 


upper receiver (3). 






>^-.»^ 


^®® 


Check gas tube (4), forward assist (5), 
and rear sight (6) for damage. Using fin- 
ger pressure, check the rear sight for 
firmness. The rear sight spring shall re- 


D - If barrel is loose on 
upper receiver, evacu- 
ate to support 
maintenance. 







Mi 


tain the rear sight in either position with 






ft 


Firmness. 


SH - If damaged, evacu- 




\^ iy 


/ 




ate to direct support 




V m^ 


/ 




maintenance. 


j*^ 


^fe^ 


F 


Check front sight post, plunger, and 


D - Charging handle (8) 


® 


mi a/Hm^ 




spring (7) for damage and corrosion. 


is defective. 


ff t/fffUL 


— ® 


Clean and lubricate them (p 2-22). Check 




^^ 


M^^ 


charging handle (8) and ejection port 


SH - Replace defective 


^ 




cover (9) for defects and proper function. 


components as 


r\ ' 


n[^m 




Check sling swivel (10) and pin/rivet(1 1 ) 


necessary. 


®-» 


"^u— 


<i) 








for damage and proper function. 





2-6 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16/M16A1 RIFLE (Cent) 



Item 
No. 



Interval 



Item To Be 

Checked Or 

Serviced 



Procedure 



Not Fully Mission 
capable If: 



CAUTION 

Do not use a wire brush to roughen surfaces. Use a well-ventilated area during 
cleaning and application of solid film lubricant. If solid film lubricant comes in contact 
with moving parts or functioning surfaces of the rifle, remove lubricant immediately 
by washing with dry cleaning solvent. 

NOTE 

Shiny met al exte rior surfaces of the rifle should be recoated wit h solid film lubricant 
(item 19, jpp D)l Clean surface with dry cleaning solvent (Item 15, fepp Dl , dry, roughen 
with abrasive cloth (item 12, ^pp Dl and apply solid film lubricant 



Quarterly 



Upper receiver and 
barrel assembly (ser- 
viceability check) 
(cent) 




Inspect upper receiver (3) finish for 
scratches or worn shiny spots. 



If scratched or worn shiny in spots, dis- 
assemble and remove all lubricant from 
surface with dry cleaning solvent (item 
15, hop DI V Wear rubber gloves (item 16, 
lapp D ) and use a wash pan (item 22. lapp| 
rn\ to apply solvent. Let parts dry thor- 



oughly. Roughen the surface using abra- 
sive cloth (item 12, App Dl and apply 
solid film lubricant (item 1 9. appi D). Al- 
low 16 to 24 hours to dry before 
handling. 

Hold barrel (2) at 40-degree angle (muz- 
zle down). Pull charging handle (8) to 
rear. Hold bolt carrier assembly (12) to 
rear and push charging handle forward. 
Release bolt carrier assembly (1 2). The 
bolt carrier assembly should close and 
lock under its own weight. If it does not, 
remove the bolt (1 3) from the carrier(1 4) 
and slide the carrier (14) (without bolt) 
back and forth in the upper receiver and 
barrel assembly. If the gas tube (4) hits 
the carrier key (15) or if the gas tube 
binds on the carrier key, try to correct 
the malfunction by adjusting (slightly 
bending) the gas tube in the area of the 
handguards. 



SH - If scratched or 
worn, to allow a shiny, 
light reflecting surface, 
apply solid film 
lubricant. 



D - If this does not cor- 
rect the malfunction, 
evacuate to direct sup- 
port maintenance. 



2-7 



ARMY TM 9-1005-249-23&P 

AIR FORCET0 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



Item 
No. 



PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16/M16A1 RIFLE (Cont) 



Interval 



Item To Be 

Checked Or 

Serviced 



Procedure 



Not Fully Mission 
Capable \t 



WARNING 



Below direct support maintenance, do not interchange bolt assemblies from one 
weapon to another. Doing so may result in injury to, or death of, personnel. 



Quarterly 



Bolt carrier assembly 
(serviceability check) 





Remove and disassemble. Visually in- 
spect bolt assembly (1 ) for cracks, espe- 
cially in the area of the cam pin hole (2). 
Check for cracks on locking lugs (3), for 
a cluster of pits or chipped bolt face (4), 
and for an elongated firing pin hole (5). 

Check for missing or broken retaining 
pin (6)/bolt cam pin (7), or cracks on bolt 
cam pin. 

Check for worn bolt rings (8). Insert the 
bolt assembly (1 ) into the bolt carrier (9). 
Turn bolt carrier assembly (9) so the bolt 
assembly (1 ) points down. The bolt must 
not drop out. 



Check extractor and spring (10) and 
ejector and spring (1 1 ) for dirt and 
serviceability. 

NOTE 



Do not remove extractor spring 
assembly from extractor except 
for replacement. 

Check bolt carrier (9) and carrier key (1 2) 
for damage and looseness. 

NOTE 



Dented carrier keys may be re- 
paired (p 2-25) using the fabri- 
cated key tool (fig E-31 fapp E) . 

Check firing pin (13) for chips or breaks. 



Pits or wear in area illustrated is permis- 
sible (14). 



Id - If defects are found, 
(evacuate to direct sup- 
Iport maintenance for 
irepair. 



Id - Replace retalninc 
Ipin/bolt cam pin. 



Id - If the bolt assembly 
fdrops out of the bolt 

'carrier due to Its own 
'weight, evacuate to di- 
irect support mainte- 
inance for repair (usu- 
ially bolt ring 
ireplacement). 

!SH - Clean, lubricate (p 
2-22) and assemble. 

D - Replace extractor 
land spring, and ejector 
and spring as 
necessary. 



D - If bolt carrier or car- 
rier key is damaged or 
carrier key is loose, 
evacuate to direct sup- 
port maintenance. 



D - If firing pin is dam- 
aged, evacuate to di- 
rect support 
maintenance. 



2-8 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16/M16A1 RIFLE (Cont) 

P 



Item 
No. 



Interval 



Quarterly 



Item To Be 

Checked Or 

Serviced 



Lower receiver and 
extension assembly 
(serviceability check) 






Procedure 



Remove buffer (1) and action sprinf 
Check buffer for cracks. 



[2). 



Check action spring {1 2) for kinks and free 
length. Free length should be 1 1 3/4 
minimum to 13 1/2 maximum inches. 



Remove rifle grip (3), spring (4), safety 
detent (5), pivot pin (6), detent (7), and 
spring (8). Clean and lubricate metal 
components (p 2-22). Also clean and lu- 
bricate pivot pin holes and spring/detent 
holes. 

Compress helical compression spring 
and takedown pin detent (9) using a jew- 
eler's screwdriver or fabricated tool de- 
picted in l appendix ElFTfig E-£ ). 



Lubricate {p 2-22) helical compression 
spring and takedown pin detent (9) by 
placing one drop of lubricant on detent 
and lowering the buttstock assembly (1 0) 
to vertical position. Allow the lubricant to 
work its way around the helical compres- 
sion spring and takedown pin detent (9). 

Check buttstock assembly (10) com- 
ponents for damage. 

Under the following conditions, hairline 
cracks (no chipped away material al- 
lowed) originating from the buttplate end 
of the buttstock are acceptable without 
repair. 

a. One hairline crack, not to exceed one 
inch in length, per side of buttstock. 

b. Two additional hairline cracks up to 
1/4 inch in length, per side of buttstock. 

c. A total of three cracks per side of 
the buttstock, originating from the butt- 
plate end, are allowable. 

Cracks in the critical area (11) at the front 
end of the buttstock are not acceptable. 



Not Fully Mission 
Capable If: 



SH - Replace buffer if 
racked. 

SH - If kinked or incor- 
rect length replace. Do 
not attempt to adjust 
spring length. 

D - Replace defec- 
tive/damaged compo- 
nents as necessary. 



D - If helical compres- 
sion spring will not 
compress, or takedown 
pin detent will not re- 
turn to its original posi- 
tion, refer to I page 2-Tn 
for repair procedure. 



D - Replace damaged 
components as 
necessary. 



2-9 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16/M16A1 RIFLE (Cont) 



Item 
No. 



Interval 



Item To Be 

Checked Or 

Serviced 



Procedure 



Not Fully Mission 
Capable If: 



Quarterly 



Lower receiver and 
extension assembly 
(serviceability check) 
(cent) 




CIneck buttstock assembly (1 0) for for- 
ward to rear movement and/or a 1 /32" 
gap between the buttstock assembly (1 0) 
and the lower receiver (11). If forward to 
rear movement and/or a 1 /32" gap ap- 
pears, tighten butt cap screw. If still not 
tight, replace buttplate. 

If movement and/or gap remains, a loose 
lower receiver extension may be the 
cause. 

NOTE 
Small amounts of side-to-side, up- 
and-down or rotational movement 
of the buttstock assembly is ac- 
ceptable without repair. 

Replace the butt plate (12) if any of the 
following conditions exist: 

(1 ) Cracks around the mounting holes 
are visible when installed on the weapon. 

(2) Cracks or separations around the 
door assembly are visible when the door 
assembly is closed. 

(3) If any crack is in excess of 1/4 inch 
in length and extends through the butt 
plate (12). 

(4) The butt plate (12) should not be 
removed other than for repair or replace- 
ment of parts at which time a new, self- 
locking screw must be used. 

Function check the magazine catch (13) 
and bolt catch (14). 

Check lower receiver (1 1 ) finish for 
scratches and worn shiny spots. 

NOTE 
If a M16/M16A1 Rifle LOWER RE- 
CEIVER is missing one third or more 
of its exterior protective finish, re- 
sulting in an unprotected/light reflect- 
ing surface, it is candidate for over- 
haul. This missing finish will be con- 
sidered a shortcoming. This short- 
coming requires action to obtain a 
replacement weapon. Once a replace- 
ment has been received, evacuate the 
original weapon to depot for overhaul. 



D If a loose lower 
receiver extension is 
suspected, remove 
buttstock (p 2-45) and 
check for tightness. If 
loose, evacuate to di- 
rect support mainte- 
nance for repair, Clean 
and lubricate all com- 
ponents before 
reassembly. 



SH - If defective, re- 
place necessary parts. 



D - If defective, evacu- 
ate to direct support 
maintenance. 



2-10 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16/M16A1 RIFLE (Cont) 



Item 
No. 



Interval 



item To Be 

Checked Or 

Serviced 



Procedure 



Not Fully Mission 
Capable If: 



Quarterly 



Quarterly 



Lower receiver and 
extension assembly 
{serviceability check) 
(cont) 

M16/M16A1 Rifle 



If scratched or worn shiny in spots, re- 
coat with solid film lubricant {item 19, 
lapp H )) as stated in item 4 (p 2-7). 



Quarterly 



Bipod assembly MS 
{serviceability check) 



Assemble as in operators manual. 

Check for broken, missing, or damaged 
parts and check over all general 
appearance. 



Check small arms sling for damage. 



Check spring tension for retention to rif le 
barrel. Check legs {1) for damage. 




Quarterly 



Annual DS safety 
and serviceability in- 
spection and gaging 



Check the DD Form 314 to insure annual 
DS safety and serviceability inspection 
and gaging has been done and that the 
next gaging and inspection is scheduled. 



D - Replace parts as re- 
quired and authorized, 
or evacuate to direct 
support maintenance 
for repair. 

SH - Replace if 
damaged. 

SH - If defective, re- 
place M3 bipod. 



D - If annual gaging 
has not been per- 
formed within the last 
year, notify direct sup- 
port maintenance. 



2-11 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



2-8. GENERAL 



Section IV. TROUBLESHOOTING 



a. This section contains troubleshooting information for locating and correcting most of the operating troubles 
which may develop in the 5.56mm Rifle M16 and M16A1, 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 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 for 
maintenance instructions 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 symptoms covered in the table. 

SYMPTOM INDEX 



Troubleshooting 

Procedures 

Page 



Failure of magazine to lock In weapon 

Failure to feed 

Failure to chamber 

Failure to lock 

Failure to fire 

Failure to unlock __._ 

Failure to extract - 

Failure to eject 

Failure to cock 

Short recoil 

Weapon cannot be zeroed 

Failure to cycle with selector lever set on AUTO 

Fires two rounds with one pull of trigger with selector lever set on SEMI {double firing) 
Fires with selector lever on SAFE or when trigger is released with selector lever on SEMI 
Bolt fails to lock to rear after firing last round 



2-i5| 


2-1 d 


2-14 


2-14 


2-15 


2-15 


1 2-16 


2-16 



I ?-16 l 

2-1 

2-191 




2-12 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



1. FAILURE OF MAGAZINE TO LOCK IN WEAPON. 

Step 1. Dirty or corroded magazine catch (1). 

Disassemble and clean. 
Step 2. Defective magazine catch spring (2). 

Replace spring (2). 

Step 3. Worn or broken magazine catch (1). 
Replace magazine catch (1 ). 

2. FAILURE TO FEED. 

Step 1. Magazine catch spring (1 ) weak or broken. 

Evacuate to direct support maintenance, 

Step 2. Magazine catch (2) defective. 

Evacuate to direct support 
maintenance. 

Step 3. Magazine catch (2) out of adjustment 
(will not retain magazine). 

Refer to operator's manual 
Step 4. Magazine catch notch (3) defective. 

Replace magazine assembly. 
Step 5. Magazine lips (4) burred or broken. 

Replace magazine. 

Step 6. Magazine follower (5) defective, 
or binds during operation. 

Replace magazine. 
Step 7. Magazine spring (6) weak or broken. 

Replace magazine. 
Step 8. Magazine tube (7) dented. 

Replace magazine. 
Step 9. Short recoil. 

Refer to I pace 2^71 






2-13 



Army tm 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



3. FAILURE TO CHAMBER. 



Step 1. Weak or broken action spring (1) (free length 11 3/4 
inches minimum to 13 1/2 inches maximum). 

Replace action spring (1) {p 2-45). 

Step 2. Obstruction in bore/chamber. 

Remove obstruction; if unable to remove obstruction 
evacuate to direct support maintenance. 




4. FAILURE TO LOCK. 



Step 1. Dirty or damaged ammunition 
(1). 



K 




r> 



U=i::=> 



Replace ammunition. 
Step 2. Bolt cam pin (2) broken or missing. 

Replace bolt cam pin (p 2-24). 

Step 3. Loose or damaged bolt carrier key (3). 

Evacuate to direct support maintenance. 
Dented carrier keys (3) may be repaired 
{p 2-22) using the fabricated key tool 

ESIB.Lilill). 

Step 4. Improperly assembled extractor spring assembly 

(4) to extractor (5). 

Assemble correctly (p 2-29). 

Step 5. Bent gas tube (6). 

Adjust/bend gas tube in area of the 
handguard to its original configuration. 
If the gas tube cannot be repaired to 
its original configuration, evacuate 
weapon to direct support maintenance. 

Step 6. Weak or broken action spring (7). 

Replace action spring (7) (p 2-45). 




2-14 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



5. FAILURE TO FIRE. 

Step 1. Broken, chipped, or deformed firing pin (1). 
Evacuate to direct support maintenance. 




Step 2. Firing mechanism (2) and/or lower receiver assembly (3) improperly assembled or has worn, 
broken, or missing parts. 

Evacuate to direct support maintenance 



Step 3. Broken, missing, or defective retaining pin (4). 
Replace retaining pin (p 2-24). 



6. FAILURE TO UNLOCK. 

Step 1. Burred locking lugs (1) on bolt assembly (2). 

Evacuate to direct support maintenance. 
Step 2. Burred locking lugs (3) on barrel extension. 

Evacuate to direct support maintenance. 
Step 3. See short recoil (p 2-17). 
Step 4. Broken bolt assembly (2). 

Evacuate to direct support maintenance. 






2-15 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



7. FAILURE TO EXTRACT. 



Step 1 . Defective extractor pin (1 ), extractor (2), and/or 
extractor spring assembly (3). 

Replace extractor pin (1 ), extractor (2), and/or 
extractor spring assembly (3) {p 2-24). 

Step 2. Short recoil. 

Refer to l page g^TI 

NOTE 



RUBBER 
INSERT 




Rubber insert and spring are an assembly. Illustration shows insert out of assembly for clarifica- 
tion only. Do not remove rubber insert from spring. 



Step 3. Badly pitted chamber. 

Evacuate to direct support maintenance, 

8. FAILURE TO EJECT. 

Step 1. Broken or missing cartridge ejector (1 ). 

Replace {p 2-29). 
Step 2. Ejector (1) stuck in bolt body (2). 

Disassemble and clean (p 2-29). 
Step 3. Weak, broken or missing ejector spring (3). 

Replace (p 2-29). 
Step 4. Short recoil. 

Refer to l page g^TI 

9. FAILURE TO COCK. 

Step 1. Worn, broken, or missing parts of firing 

mechanism {1 ). 

Evacuate to direct support 
maintenance. 

Step 2. Short recoil. 

Refer to Ipaqe 2-171 




2-16 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



10. SHORT RECOIL. 

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

Evacuate to direct support maintenance if rings are worn, broken or missing {p 2-30). 




Step 2. Partially plugged gas system because of carbon build up in gas tube. 

Evacuate to direct support maintenance. 
Step 3. Carbon buildup in the narrow passage of the bolt carrier key. 

Clean with CLP {item 9, a fltp U) b r RBC (item 11, bpp U| . See operator's manual, 
Step 4. Gas leakage caused by broken or loose gas tube (2) around front sight base (3). 

Evacuate to direct support maintenance. 




Step 5. Improper alignment of gas tube (2) and carrier key {4), 

Refer to l oaae 2^241 
Step 6. Loose carrier key (4). 

Evacuate to direct support maintenance. 




2-17 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



11. WEAPON CANNOT BE ZEROED. 

Step 1. Bent or bulged rifle barrel assembly (1). 

Evacuate to direct support maintenance. 




Step 2. Barrel assembly out of alignment with rear sight on upper receiver. 

Evacuate to direct support maintenance. 
Step 3. Corroded front sight post (2). 

Disassemble, clean and lubricate (p 2-37). 
Step 4. Corroded rear sight (3). 

Clean and lubricate. Evacuate to direct support maintenance. 




(D 



01 » 




2-1 8 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



12. FAILURE TO CYCLE WITH SELECTOR LEVER SET ON AUTO. 

Faulty selector lever (1 ). 

Evacuate to direct support maintenance. 

13. FIRES TWO ROUNDS WITH ONE PULL OF TRIGGER WITH SELECTOR LEVER (1) SET ON SEMI (DOUBLE FIRING). 

Perform function test. 

If any part of function test (p 2-53) fails, evacuate to direct support maintenance. 

14. FIRES WITH SELECTOR LEVER (1) ON SAFE OR WHEN TRIGGER IS RELEASED WITH SELECTOR LEVER ON 
SEMI. 

Worn, broken, or missing parts of firing mechanism. 

Evacuate to direct support maintenance 




2-19 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



15. BOLT FAILS TO LOCK TO REAR AFTER FIRING LAST ROUND 



Step 1 . Magazine follower (1 ) worn or broken. 

Replace magazine. 
Step 2. Magazine 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 direct support maintenance. 





2-20 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

Section V. DECONTAMINATION OF RIFLES AND ARMS ROOMS 
2-10. DECONTAMINATION OF SIGHTS ACTIVATED WITH TRITIUM (MS). 

a. Identification. Tritium sights will be marked with the assembly data and the radiation symbol and stamped H3, 9 
mc . 

b. Damage Determination. Evidence of a break in the glass container for the H3 will be a lack of illumination (assur- 
ing the expiration data for the sight has not been exceeded). Radiation from the sight is extremely low and CANNOT 
be detected with standard issue radiation detectors, i.e., AN/PDR-27. 

c. Contamination. The tritium isotope used in the low light level sight Is in a gaseous state and will rapidly diffuse 
into the atmosphere in the event of breakage. Very little residual contamination should be left on the rifle. All illumina- 
tion will cease upon loss of H3 gas. 

WARNING 



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. 

d. Decontamination. When a broken sight is found, the sight MUST be removed and turned in for disposal in ac- 
cordance with AR 385-1 1 . After removing the sight, the rifle should be cleaned with dry cleaning solvent {item 15, 

laPD U ). Wear rubber gloves (item 16, boo DD and use a wash pan (Item 22. 1 aop 1 )) to apply solvent. Let dry, then 
lubricate (p 2-22). 

e. Requirements. Because its small volume of gas and its low energy of emitted radiation. H3 does not pose a 
health hazard to the user. Current Army regulations NRG license conditions and Title 10, Code of Federal Regulations, 
Part 20 require that the above actions be carried out. 

2-11. DECONTAMINATION OF SIGHTS ACTIVATED WITH PROMETHIUM (PM 147). 

NOTE 

PM 147 is no longer available for issue and must be replaced. It is being replaced with 
tritium (H3). 

a. General. When a sight activated with promethium (PM 147) is found, the sight MUST be removed and turned in 
for disposal in accordance with AR 385-1 1 . Contact the local RPO. 

b. Identification. Promethium sights are marked with the assembly date, radiation symbol, and PM 147, 1 mc. 

c. Decontamination. If a sight activated with promethium (PM 147) is found, conduct a survey under the direction 
of the local RPO. Decontaminate as required in accordance with local procedures. 

Section VI. MAINTENANCE PROCEDURES 

2-12. INITIAL SETUP. The following 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. 



2-21 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

c. Do not scratch, etch or stamp numbers, letters or any other information on bolt, bolt carrier, buttstock or 
other piece parts. 

d. The normal standard equipment condition is that the item is removed from end item or next higher assembly 
and is in the assembled condition. Equipment Condition is not listed unless some other condition is required. 

e. The approximate time required is listed on the applicable Maintenance Allocation Chart (MAC). 

f. When the term evacuate to direct support maintenance is used, the entire weapon must be evacuated. 

NOTE 



Solid Film Lubricant (SFL) is the authorized touch up for the M16/M16A1 Rifle and 
may be used on up to one third of the exterior finish of the weapon. 
FOR CONUS USE ONLY: Solid Film Lubricant may be used as a touch up 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% of the exterior surface of the Upper Receiver and Barrel 
Assembly protected with SFL. Prior to application of SFL the surface must be 
thoroughly clean and inspected for corrosion and/or damage. If corroded or 
damaged, the part must be repaired or replaced prior to application of SFL. Continued 
use under combat conditions would result in an unprotected surface when the SFL 
wears off. This would result in a large light reflecting surface and accelerated 
deterioration of the unprotected surface. Therefore, Divisional Combat Units and 
units which fall under the definition of Rapid Deployment type must adhere to the 
limitation of NOT over 1/3 of their exterior surface covered by SFL. 

2-13. LUBRICATION GENERAL. 

a. Whenever the term or instruction '"lubricate" is cited in this TM, it is to be Interpreted to mean CLP, (item 9, 
I aPD D ). LSA (item 21 , laop U ^. or LAW (item 20, lapp PI ) 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 weapon Either may 
be used at -10°F and above. However, do not use both on the same weapon at the same time. 

c. LAW is the lubricant to use during cold arctic conditions, +10° F and below. 

d. Any of the lubricants may be used from -10°F to +10°F. 







n F 


1 Ifl'^F 




OLr 


1 1 u r 

-10°F 







LAW 



e. Do not mix lubricants on the same weapon. The weapon must be thoroughly cleaned during change from 
one lubricant to another. Dry Cleaning Solvent (SD) (item 15, fepp Dl is recommended for cleaning during change 
from one lubricant to another. 



f. Rifle Bore Cleaner (RBC) (item 1 1 , App Dl may be used to remove carbon buildup in the bore and other 
portions of the weapon. 



2-22 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



2-14. MAJOR COMPONENTS OF M16/16A1 RIFLE 



u 



This task covers disassembly. 



INITIAL SETUP 

Applicable Configuration 

M16/M16A1 Rifle 

References 

■ TM 9-1005-249-10 I foperator's manual) 

Equipment Condition 

Weapon assembled. 

General Safety Instructions 

Before starting an inspection, be sure to 
clear the weapon. Do not keep live am- 
munition near the work area. 



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

Before starting an inspection on a weapon equipped 
with a low light level sight, check for damage to the 
sight and decontaminate if required. See procedures 
on rpage 2-211 

Below direct support maintenance, do not interchange 
bolt assemblies from one weapon to another. Doing 
so may result in injury to, or death of, personnel. 



DISASSEMBLY 




a. Refer to operator's manual. 

b. Remove cartridge magazine (1), small arms sling 
(2), bolt carrier assembly (3), charging handle 
assembly (4), upper receiver and barrel assembly 
(5), from lower receiver and extension assembly 
(6). 



2-23 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-15. BOLT CARRIER ASSEMBLY. 



This task covers: 

a. Disassembly 

b. Cleaning 

c. Inspection/Repair 



d. Lubrication 

e. Reassembly 



INITIAL SETUP 

Applicable Configuration 

M16/I\/I16A1 Rifle 

Tools 

Small Arms Repairman Tool Kit 
SC 5180-95-CL-A07 (19204) 
Key tool ifio E-3.1 boo Eft 

Materials/Parts 

Cleaner, lubricant and preservation (CLP) 

{item 9, bpp DH 
Cleaning compound, rifle bore (CLP) 

(item 1 1 , App PI 
Lubricating oil, weapons (LAW) (item 20, hpp n|i 
Lubricating oil, weapons (LSA)(item 21 , fapp DD 



Equipment Condition 

Bolt carrier assembly removed 

Reference 

ITM 9-1QQ5-249-1Q~l (Operator's manual) 

General Safety Instructions 

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

Do not interchange bolt assemblies from one weapon 
to another. Doing so may result in injury to, or 
death of, personnel. 



a. DISASSEMBLY 



WARNING 

Do not interchange bolt assemblies from 
one weapon to another. Doing so may 
result in injury to, or death of personnel. 

CAUTION 



Do not spread or close legs 
of firing pin retaining pin (1). 



1. Remove firing pin retaining pin (1). Lower rear 
end of key and bolt carrier assembly (2) and 
catch firing pin (3) as it drops out. 

2. Rotate bolt cam pin (4) 1/4 turn and lift straight up to remove. 

3. Remove bolt assembly (5) from key and bolt carrier assembly (2 

NOTE 




For disassembly of bolt assembly (5), se d page 2-29J 



2-24 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



b. CLEANING 



Clean all items (operator's manual). Remove carbon deposits using CLP or RBC. 



c. INSPECrrON/REPAIR 



I a 1 Inspect carrier key {1 ) for dents, distortion or looseness. If dented, straighten {see step 2 on next page). If 
loose, evacuate to direct support maintenance. 




(b) Inspect firing Pin (2), retaining pin (3), and cam pin (4) for cracks, mutilation, or excessive wear. Replace if 
unserviceable. 

(c) Inspect bolt assembly (5) for damage or excessive wear. See l pace 2-30 for repair procedures. 

(d) Inspect firing pin (2) for breaks or if tip is mutilated. Evacuate to direct support maintenance if unserviceable. 
Pits or wear in area illustrated (6) is permissible. 

(e) Inspect key and bolt carrier assembly (7) for damage or wear. If unserviceable, evacuate to direct support 

maintenance. 



2-25 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-15. BOLT CARRIER ASSEMBLY (CONT). 



c. INSPECTION/REPAIR (CONT) 





EDGE OF BENCH 



n n in 

[ Mm I t un n y s t h n eit is H d y lin g th fo lln i^ g p lo c H y le lo n s ne th I Ih s liil ' 
in 9 Inc e is n t d iie MH lo Ih Hln Hn g s cm s a H Ih t th the p o itin is n t n ing t d 
D r fhit d h r n d nig in i it q y iie n m t. S n I m ing e m e H « o y id p nn it io s s h p s p re s n le 
i h n 1 h h I n d ; n I y h n n e t o g 1 1 h i d y i i n ; I n M i o n 1 1 p e n t i n . 

Straighten small dents and/or distortions in carrier key (1 ) using fabricated key tool (8) as follows: 

(a) Place the key and bolt carrier assembly (6) in a vertical position, supported in a manner that contact is made 
with the rear surface of the carrier key (1). 

(b) Insert the small end of the key tool (8) into the tube portion of the key. 

(c) Strike the large end of the key tool (8) lightly with a 3-ounce, soft-brass hammer. 

(d) Repeat striking (gently) until carrier key (1) is reformed to original configuration. 

(e) If carrier key cannot be reformed to original configuration, evacuate to direct support maintenance. 



2-26 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



d. LUBRICATION 



Lubricate all items using CLP, LSA or LAW (p 2-22) or {operator's manual). 



e. REASSEMBLY 



1 




WARNING 

Do not interchange bolt assemblies from one weapon to another. Doing so may result 
in injury to, or death of, personnel. 

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

NOTE 

Before installing bolt assembly, check to see that the ring gaps are staggered to prevent 
loss of gas pressure. 

(a) Install bolt assembly (1) in key and bolt carrier assembly (2). 

(b) Install bolt cam pin (3} and rotate one quarter turn to secure bolt assembly (1). 



2-27 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-15. BOLT CARRIER ASSEMBLY (CONTl, 



e. REASSEMBLY (CONT) 




NOTE 
Firing pin retaining pin must be installed from the left side only. 

(a) Hold key and bolt carrier assembly (2) in vertical position and drop firing pin in position. 

(b) Install firing pin retaining pin (5) from left side only. Check proper installation by attempting to shake out firing 
pin. 



2 8 



2-16. BOLT ASSEMBLY. 



ARMY TM 9-1005-249-23&P 
AIRFORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M 8370. 9 



This task covers: 

a. Disassembly 

b. Cleaning 

C. Inspection/Repair 



INITIAL SETUP 

Applicable Configuration 

M16/M16AT Rifle 

Tools 

Small Arms Repairman Tool Kit 
SC 5180-95-CL-A07 (19204} 

Materials/parts 

Cfeaner, lubricant and preservative (CLP) 

(item 9. app D) 
Cleaning compound, rifle bore (RBC) 

(item 1 1, app D) 
Lubricating oil, weapons (LAW) (item 20, app D} 
Lubricating oil, weapons (LSA) (item 2 1, app D) 



d. Lubrication 

e. Reassembly 



Reference 

TIVl 9-1005-249-10 (Operator's manual) 

Equipment Condition 

Bolt carrier assembly removed 

General Safety Instructions 

Do not interchange bolt assemblies from one 
weapon to another. Doing so may result in 
injury to, or death of, personnel. 

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



a. DISASSEMBLY 



1 




NOTE 

Do nol separate cartridge extractor and ex- 
tractor spring assembly unless replacement 
of either or both is required. 

Do not remove the insert from the extractor 
spring assembly. 



(a) Push out extractor pin (1) using a 3/32 punch and remove cartridge extractor <2) and extractor spring 

assembly (3) as a unit. 

NOTE 

There are two types of extractor springs. The earlier design does not contain an 
insert The latest design contains an insert All old type extractor springs must be 
replaced. 

Do not remove extractor spring assembly from cartridge extractor unless either part 
requires replacement 

(b) If required, twist extractor spring assembly (3) counter-clockwise while gently pulling on it, to remove from 
cartridge extractor (2). Do not remove/lose rubber insert from spring assembly. 



2 9 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-16. BOLT ASSEMBLY (CONT) 



a. DISASSEMBLY (CONT) 




Ji-<D 



CAUTION 



Be sure to use vise jaw protective caps. 

Hold bolt body in vise and remove spring pin (4} us- 
ing punch and hammer. 



^ WARNING 




^^ To avoid injury to your eyes, use care when 


removing and installing spring loaded parts. 


^^fe^ I 


\ 


\^\^ ® \ 


\ 


^^$S^Sc5v^ 1^^ \ 




^^^^J 


\ ''k 


®-^ 


\4 


Remove punch, be sure to catch cartridge 


ejector (5) and 


ejector spring (6) to prevent loss. 





b. CLEANING 



CAUTION 
Do not distort extractor pin or spring assembly during cleaning. 

Clean all items (operator's manual). Remove carbon deposits with CLP or RBC. 



c. INSPECTION/REPAIR 



1. Check bolt rings (1} for proper spacing, (approximate- 
ly 1/3 apart). 

2. With retaining pin and cam pin removed from bolt 
carrier assembly (2), check for worn bolt rings (1) as 
follows: Insert bolt assembly (3) all the way in bolt 
carrier. Turn bolt carrier downward as illustrated. If 
bolt assembly falls out, rings are worn. Evacuate to 
direct support maintenance. 

3. Inspect for cracks, especially around cam pin hole 
(4), and locking lugs (5). 

4. Inspect extractor, extractor spring assembly, and ex- 
tractor pin for cracks, breaks, chips, and other 
damage. Pay close attention to extractor lip. 

5. Inspect ejector and ejector spring for cracks, breaks, 
and chips. 

6. Replace all authorized unserviceable items. 

7. Repairs not authorized at this level, evacuate to direct support maintenance. 

8. The inspection of the worn bolt rings can be accomplished with the bolt assembled or disassembled. 





KD 



2-30 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



d. LUBRICATION 



Lubricate all items with a light coat of CLP, LSA, or LAW (p 2-22). 



e. REASSEMBLY 



1 



WARNING 

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

Do not interchange bolt assemblies from one weapon to another. Doing so may result 
in injury to, or death of, personnel. 



CAUTION 



Be sure to use vise jaw protective caps. 



ja) Hold bolt body ID tn a vise and start spring pin (2) in hole. 

(bl Install ejector spring j3) and cartridge ejector (4). 

|c) Align groove on cartridge ejector (4) so that spring pin (2) can be installed. 





la) Compress and hold ejector spring and cartridge ejector in place with a 3/8 inch punch. Install spring pin (2) us- 
ing a hamrnero 

(bl Complete installation of spring pin (2) so that the ends are flush with the outside of the bolt body <1). 



2-31 



aARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



2-16. BOLT ASSEMBLY (CONT). 



e. REASSEMBLY (CONT) 



NOTE 



There are two types of extractor springs. The earlier design does not contain an 
insert. The latest design (with an insert) is the only authorized repair part. All old type 
extractor springs must be replaced. 




NOTE 



Do not disassemble rubber insert from spring assembly. 



If exiractor spring was removed, insen large end of extractor spring assembly (5) into cartridge extractor (6) anc 
seal by pushing and turning clockwise, until it is seated. \ 



(a) Position cartidge extractor (6) and extractor spring 
assembly (5) on bolt body (1). 

(b) Compress spring assembly (5) and cartridge ex- 
tractor (6) to align holes. 

(c) Install extractor pin (7) by hand. 




2-32 



ARMY TM 9-1 005-249-2WP 

AIR FORCE TO 11 W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



2*17. CHARGING HANDLE ASSEMBLY. 



This task covers; 

a. DisassembSy 

b. Cleaning 

c. Inspection/Repair 



d. Lubrication 

e. Reassembly 



INITIAL SETUP 

Application Configuration 

M16/IVn6A1 Rifle 

Tools 

Small Arms Repairman Tool Kit 
SC 5l80-95.CbA07 (19204) 

Materials/Parts 

Cleaner, lubricant and preservative (CLP) 

(item 9, app D) 



Lubricating oil, weapons (LAW) (item 20, app D) 
Lubricating oil, weapons (LSA) (item 21, app D) 

References 

TM 9-1005-249-10 (operator's manual) 

Equipment Condition 
Charging handle removed 





WARNING 



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





1« Remove spring pin (1) from charging handle (2) using a hammer and 1/16 inch punch. 

2. As punch is withdrawn, catch charging handle latch (3) and helical spring (4) to prevent loss. 



2-33 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-17. CHARGING HANDLE ASSEMBLY (CONT). 



b. CLEANING 



Clean all items (operator's manual). 



c. INSPECTION/REPAIR 



Inspect all items for breaks, cracks, or mutilation. Replace all authorized unserviceable items. 



d. LUBRICATION 



Lubricate all items, with a light coat of CLP, LSA, or LAW (p 2-22) (operator's manual). 



e. REASSEMBLY 



1. Position helical spring (1) and charging handle latch 
(2) in charging handle (3). Align holes and hold in 
position. 

2. Install spring pin [A] using a hammer. Make pin 
flush. 





2-34 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11 W3-5-5-24 

COAST GUARD COMDTINST M837a9 



2-18. UPPER RECEIVER AND BARREL ASSEMBLY (HANDGUARD ASSEMBLY). 



This task covers: 




a. Disassembly 

b. Inspection/Repair 


c. Reassembly 


INrTIAL SETUP 




AppHcabie Configuration 

M16/M16A1 Rifle 


Equipment Condition 

Weapon assembled. 


Reference 
TM 9-1005-249-10 (operator's manual) 





a. DISASSEMBLY 



1 



CAUTION 

Do not use a screwdriver or any 
other tool when removing the hand- 
guards. Doing so may damage the 
handguard and/or slip ring. 

Do not remove heat shields from 
handguards. Doing so will damage 
the heatshield and the handguard 
will have to be replaced. 

NOTE 

Refer to operator's manual for "buddy 
system" procedure on removing handguards. 



Push down on handguard slip ring (1) and lift 
the handguard (2) up and out. 




1 

Push down on handguard slip ring (1) and lift the other 
handguard (2) up and out. 


^ r 

Us 


1 




"1/ -. 


'$ 


d 



2-35 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-18. UPPER RECEIVER AND BARREL ASSEMBLY (HANDGUARD ASSEMBLY) (CONT). 



b. INSPECTION/REPAIR 



1. inspect handguard assembly for breaks, 
separations, and cracks. 

2. Breaks and separations of material which 
prevent proper retention or interfere with 
functioning of the weapon will be cause for 
handguard rejection and replacement. 

3. Cracks up to one inch in length are accept- 
able provided they do not extend into the 
handguard retaining flange (1) (critical area). 

4. Each handguard assembly may have up to 
two of the three front retaining tabs (2) 
missmg. If all three front tabs are missing, 
the handguard assembly must be replaced. 

5. Replace severely cracked handguards. Handguards that have a heatshield loose enough to rattle when 
installed on the rifle must be replaced. 




c. REASSEMBLY 



- NOTE 






1 Refer to operator's manual for "buddy system' 


procedure on Installing handguards. 




Install top of handguard (T) in tube cap (2) while push- 
ing down on handguard slip ring (3). Push bottom of 
handguard (1) m place and release handguard slip ring 
(3) to lock handguard in place. 


(2 \ ^^^^, 








i 








1 








1 






V'^B 


V? . 


'^^ 




^J=SB5'=v^.— — t 


D 




''^lu'^j^lnlH L \ 






^^^ III 11^9 1 *^M 

^^^ jfr^afr^^«i ■'21 





2-36 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



2 






P^ 


Install top of the other handguard (4) in handguard cap 
{2) while pushing down on handguard slip ring (3). Push 
bottom of handguard (4} in place and release handguard 
slip ring (3) to lock both handguards in place. 


4 


i5 


; 








^-^^ 



2-19. UPPER RECEIVER AND BARREL ASSEMBLY. 



This task covers: 

a. Disassembly 

b. Cleaning 

c. Inspection 

d. Repair 



e. Lubrication 

f. Reassembly 

g. Mechanical Zero Procedures (A.F. only) 



INITIAL SETUP 

Application Configuration 

M16/M16A1 Rifle 

Tools 

Front sight post and low light level front sight 
post removal/installation tool (fig E-1, app E) 

Small Arms Repairman Tool Kit SO 5180-95-CL- 
A07 (19204) 

Materials/Parts 

Cleaner, lubricant and preservative (CLP) (item 

9, app D) 
Cleaning compound, rifle bore (RBC) (item 11, 

app D) 
Lubricating oil, weapons LAW (item 20, app D) 
Lubricating oil, weapons LSA (item 21, app D) 

Reference 

TM 9-1005-249-10 (operator's manual} 

Equipment condition 

Handguards removed. 

Upper receiver and barrel assembly removed 
from lower receiver. 



General Safety Instructions 

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

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



4.4 




Barrel assembly may be equipped with a low light 
level sight. The low light level sight contains 
radioactive material. If so equipped, do not insert 
metal objects into the post slot or otherwise treat 
roughly to cause breakage of the radioactive 
element. 



2-37 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-19. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



a. DISASSEMBLY 



1 




ELEMENT SEEN 
FROM 2 SIDES ONLY 

RADIOACTIVE 

CONTENT 
9MC 



DATE OF 
MANUFACTURE 




LUMINOUS 
MATERIAL 
H3 FOR TRITIUM 



RADIATION 
SYMBOL 



STANDARD FRONT 
SIGHT POST 



FRONT LOW LIGHT LEVEL 
POST ASSEMBLY 



Prior to disassembly, inspect upper receiver and barrel assembly to determine type of front sight installed, standard 
or !ow light level. If a radioactive low light level sight is installed and if it has been damaged, see warning page and 
Chapter 2,1 Section V. 



FRONT SIGHT POST AND LOW 

LIGHT LEVEL FRONT SIGHT 

POST REMOVING 

AND INSTALLATION 

TOOL 



FRONT LOW LIGHT LEVEL 
POST ASSEMBLY 




WARNING 



If weapon is equipped with lo w ligh t level 
front post assembly, see paqe l 4-2 f or usable 
life and maintenance. 

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

Remove front sight post (1) using appropriate end of 
fabricated tool. 



2-38 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



0— d 




Catch front sight detent (2) and helical spring 
(3) to prevent loss. 




NOTE 

Disassemble swivel only if repair is necessary. 

If necessary, knock out rivet (4) with a hammer 
and punch and remove swivel (5). Discard rivet (4). 





•^— ® 



NOTE 

Do not disassemble further unless repair is necessary. EjecUon port cover pin (7) 
may bind against the forward assist housing on the M16A1 rifle and require some 
additional force to remove. 

(a) Using tvi^o flat tip screwdrivers, remove retaining ring (6) and slide ejection port cover pin (7) out to the rear. 

(b) Catch helical spring (8) and ejection port cover (9) to prevent loss. 



2-39 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 1 1W3-5-5-24 
COAST GUARD COMDTIIMSTM8370.9 



2-19. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



b. CLEANING 



Clean all items with CLP or RBC (operator's manuall 



c. INSPECTION 



1 

(a) 


Inspect front sight base for chips, breaks and cracks. If damaged, evacuate to support maintenance. 


(b) 


Inspect low light level sight (if installed) for broken sights and loss of illumination. 


(cl 


Inspect all parts for serviceability. 



(a) Inspect barrel for pits, dirt and rust in bore, burrs, broken or worn locking lugs, and surface cracks and defects, 



ACCEPTABLE 





NOT ACCEPTABLE 



(1) Pits no wider than a land or groove and 3/8 inch or less in length are allowable in the bore. 

(2) Lands that appear dark due to coating of gilding metal from projectiles are allowable. 

(3) Stripping of lands and grooves shall not be cause for rejection unless so determined by barrel erosion gage. 

(b) Inspect chamber for pitting. Fine pits, or fine pits in a densely pitted area, are allowable. Pits 1/8 inch in length 
are cause for rejection. 

<c) Inspect bore for ringing. Definitely ringed bores or bores ringed sufficiently to bulge the outside surface of the 
barrel are causes for rejection. 

(d) If the barrel is rejected in accordance with the above criteria, evacuate to support maintenance. 



.2-40 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



d. REPAIR 









For touch up of M16/M16A1 Rifle, see 


page 2-22. 




Replace all authorized unserviceable parts. If repair 
tenance. 


is not authorized at this level, evacuate to direct support main- 



e. LUBRICATION 



Lubricate all items with a light coat of CLP, LSA, or LAW (p 2-22) or operator's manual. 



f. REASSEMBLY 



1 




(a) If previously disassembled, position cover (1) and spring (21 on upper receiver (3) with short leg of spring to 
the rear pointing up toward top of receiver. 

NOTE 

Legs of spring must be positioned and pretensioned before the pin is installed. 

(b) Hold spring (2) short leg in this position and turn long leg 1/2 turn clockwise <as viewed from front of receiver 
(3)) to increase spring tension. 

Cc) Position long leg of spring (2) to be on inside of cover (1) when it is closed. Hold spring and cover in this posi- 
tion and install pin {4) and retaining ring (5). 



2-41 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-19. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



f. REASSEMBLY (CONT) 




If previously disassembled, position sling swivel (6) 
and install new tubular rivet (7) using center punch 
and hammer to spread and flare the hollow head of 
the tubular rivet. 




Install helical spring (8). Position and depress front 
sight detent (9) with punch. 



Install front sight post (10) using 
appropriate end of fabricated tool. 



FRONT SIGHT POST AND 

LOW LIGHT LEVEL FRONT 

SIGHT POST REMOVING 

AND INSTALLATION TOOL 





DEPRESS 
DETENT 



2-42 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



g. MECHANICAL ZERO PROCEDURES 



Mark a piece of plastic card stocl< or rigid paper with 
lines from 1 to 5mm in 1 mm increments. Set the card 
on the front sight frame and check the height of the top 
of the front sight post. 




Adjust the front sight so the top of the front sight post 
is 5mm above the machined surfaces of the front sight 
frame. 




2 -1 3 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-19. UPPER RECEIVER AND BARREL ASSEMBLY (CONT) 



g. MECHANICAL ZERO PROCEDURES (CONT) 



Visually check the front sight post top height by using the marked plastic or paper card. Card must set level on the 
machined surfaces of the front sight frame to obtain an accurate reading. 




NOTE: Procedure will give an approximate battle sight zero to most Ml 6 rifles. Once the above steps are com- 
pleted, the rifle will be mechanically zeroed for 250 meters using the unmarked or short-range aperture and at 375 
meters using the "L" or long-range aperture. The above steps can also be used before firing a new or newly 
assigned rifle. Use the procedure to check rifles stored in preferred packaging during routine inspections. This will 
help ensure people armed with the rifles will stand a better chance of hitting an enemy if the rifles must be used 
before a live fire zero can be made. Whenever possible, zeroing of the rifle should be accomplished using ball am- 
munition on a 25 meter zeroing target using the "L" aperture. 



2-44 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



2-20. LOWER RECEIVER AND EXTENSION ASSEMBLY. 



This tasks covers: 

a. Disassembly 

b. Cleaning 

c. Inspection 



d. Repair 

0. Lubrication 

f. Reassembly 



INITIAL SETUP 

Applicable Configuration 

iVi16/M16A1 Rifle 

Tools 

Small Arms Repairman Tool Kit 

SC 5180=95"CL=A07 (1 92041 

Pivot Pin Removing Tool Ifig E"2,llapp E! 



Pivot Pin Installation Tool |(fig E-5,japp El 



Materials/parts 

Cleaner, l ubricant and preservative (CLP) (item 9 

app D} 
Lubricant, solid film (SLF) (item 19 j app Dj 
Lubricating oil, weapons (LAW) (item 2 0,1 app D 



Reference 

TM 9-1005-249-10 (operator's manual) 

Equipment Condition 

Lower receiver and extension assembly removed. 

General Safety Instructions 

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



Lubricating oil. weapons (LSAI (item 21, app D) 
Screw, Self-Locking (Butt=Cap Screw) (item 28, 
pg C-10) 



a. DISASSEMBLY 



1 




Using flat tip screwdriver, reach inside rifle grip and 
remove screw (1) and lock washer (2). 



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




Carefully remove rifle grip (3) and catch helical spring 
(4) and safety detent (5) to prevent loss. 



2-45 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-20. LOWER RECEIVER AND EXTENSION ASSEMBLY (CONT) 



a. DISASSEMBLY (CONT) 



NOTE 

The butt cap screw is a self -locking screw. 
Due to the critical nature of the parts con- 
cerned, if the butt cap screw is removed, 
it must be discarded and replaced with a 
new one. 

Remove butt cap screw (6). 




WARNING 

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

Remove buttstock assembly (7) carefully and catch 
helical spring (8), detent (9), takedown pin (10), and 
stepped spacer (11) to prevent loss. 




WARNING 

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

Insert fabricated pivot pin removing tool (12) to com 
press detent. Turn pivot pin (13) a quarter-turn. 
Remove tool and pin. 

NOTE 

Catch detent and spring as pivot pin is 
removed (see step 6 on next page). 




2-46 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



Be sure to hold cupped hand in front of detent (141 and 
helical spring (15) to prevent loss of detent and spring. 




WARMING 
To avoid injury to your eyes, ust 

7 when removing and installing spring- 
loaded parts. 
NOTE 

Make sure the hammer is cocked and the 
selector level is not set on AUTO before 
removing the buffer assembly. 

Press buffer assembly 06) in. Using screwdriver, 
depress buffer retainer (17) and release buffer 
assembiy 06) and action spring (18K Rennove 
buffer assembly f16| and action spring (18) from 
receiver while depressing retainer (17). 

NOTE 
Early type buffer assembly (19) must 
be replaced. 






PRESS BUFFER ASSEMBLY 
IN ABOUT 1/4 INCH 



I DEPRESS BUFFER 

I RETAINER 



b. CLEANING 



Clean all items (operator's manual). 



c. INSPECTION 



inspect buffer assembly (1 , 2, or 3) for cracks or damage. 

(a) Some old buffers (1) have a hole with pin installed which 
protFudes equally on each side approximately 1/32 inch. 

(b) Some buffers (2) have a hole in the housing but no pin. 

(cl New buffers (3) do not have a hole in buffer body or a pin. 

All configurations (1, 2, or 3| may be utilized. However, if 
cracked or damaged, replace. 




2-47 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-20. LOWER RECEIVER AND EXTENSION ASSEMBLY (CONT), 



c. INSPECTION (CONT) 



Check free length of action spring (4). The free length 
must be between 1 1 3/4 inches minimum and 13 1/2 
inches maximum. Do not attempt to adjust spring 
length. 




FREE LENGTH 



(a) Inspect lower receiver (5) (without further 

disassembly) for leglbilitv of serial number. If the 
serial number is hard to read, notify direct support 
maintenance. 

NOTE 

Only direct support maintenance is 
authorized to restamp the serial number. 

ib) Check lower receiver extension (6) for looseness 
and corrosion. If loose, evacuate to direct support 
maintenance. If corroded, clean area and touch up 
with solid film lubricant. 

(c) Inspect for missing or damaged parts. Inspect 
finish of lower receiver for shiny spots. Touch up 
with solid film lubricant as required. 

(d) Visually inspect all other parts for unserviceable or missing parts. Replace defective or missing parts, 




d. REPAIR 



For touch up of M16/M16A1 Rifle, use SFL (see p 2-22). 




Replace all authorized unserviceable parts. If repair is not authorized at this level 


evacuate to direct support 


maintenance. 





e. LUBRICATION 



Lubricate all metal components with a light coat of CLP, LSA, or LAW (p 2-221 (operator's manual). 



2-48 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



f. REASSEMBLY 



1 



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 level is not on AUTO before in- 
stalling the buffer assembly. 




Press action spring (1) and buffer assembly (2) in until retainer (3) snaps up and holds them in place. 





Install pivot pin installation tool (4). Insert helical spring (5) and detent (6). Compress detent in recess with punch 
and rotate tool 



2-49 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-20. LOWER RECEIVER AND EXTENSION ASSEMBLY (CONT) 



f. REASSEMBLY (CONT) 



NOTE 

Rounded end of detent must be in the groove 
of the pivot pin (7) when assembly is complete. 



Position pivot pin (7) to keep detent depressed wh 
removing fabricated pivot pin removing tool (6). Slide pin 
(7) into hole. Rotate pin and receive detent. 





CAUTION 

Do not kink the detent spring (10) during assembly. 

NOTE 

Pointed end of detent (9) must be in the groove of takedown pin (8) when assembly Is 
complete. 

(a) Install takedown pin (8) with groove toward the rear. Install detent (9) and spring (10) from the rear. 

NOTE 

Stepped spacer (11) and butt-cap screw (14) PN 93491 28 are required when using 10.103 
inch long buttstock PN 93491 21 . When using old 9.478 in. long buttstock PN 8448651 , 
stepped spacer (11) is not required but butt cap screw PN 8448627, NSN 
1005-00-992-6657. is required. 

(b) Install spacer (111 on receiver extension (12) and carefully slide buttstock assembly (13) on to compressed 
helical spring (10). 

NOTE 

Installing the buttstock assembly is easier if the lower receiver is held in a vertical posi- 
tion with the end of the lower extension pointed up. 



2-50 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




NOTE 

The butt cap screw (14) is a self -locking screw, and if removed, it must be discard- 
ed and replaced with a new one. 

Secure buttstock assembly (13) in place with a new butt cap screw (14) as follows: 



Tighten the screw until the tapered screw head 
has seated under normal pressure and resistance is 
felt. 



Tighten screw an additional quarter turn, if butt cap 
screw continues to loosen under use, it should be 
replaced with a new one. 




WARNING 
When utilizing the enhanced rifle grip (it has a bump between the second and third 
finger for a better grip) PN 9349127, rifle grip screw, PN AN501D416-18 (1-1/8 
In.) or AN501D416-16 (1 in.) are the authorized screws to be used with the 
enhanced grip. Any screw longer than 1-1/8 in. used with 9349127, could cause a 
hazardous situation. Also, ensure the washer is in place. 

(a) Install detent (15), pointed end first, and spring (161 into bottom of lower receiver (17). 

NOTE 
A portion of the spring will fit in a hole in the rifle grip. 

(b) Carefully install rifle grip (18| to compress spring (16). Secure grip (18) in place with lockwasher (19) and 
screw (20). 



2-51 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



2-21. BUTTSTOCK ASSEMBLY. 



This task covers: 

a. Disassembly 

b. Cleaning 

c. Inspection 



d. Repair 

e. Lubrication 

f. Reassembly 



INITIAL SETUP 

Application Configuration 

M16/M16A1 Rifle 



Tools 

Small Arms Repairman Tool Kit 
SC 5180-95-CL-A07 (19204) 



Materials/Parts 

Cleaner, lubricant and preservative (CLP) 

(item 9, app D) 
Lubricating oil, vweapons (LAW) (item 20 app D) 



Lubricating oil, weapons (LSA) (item 2 1,|app U) 



Equipment Condition 

Lower receiver and extension assembly removed 
buttstock assembly removed. 



a. DISASSEMBLY 



1 




Using screwdriver, remove self-locking screw (1), 
rear sling swivel (2) and butt plate group (3) from 

buttstock [A] 

NOTE 



The buttstock assembly may utilize a 
buttstock (4) which is 10.103 inches long 
(PN 9349126) or 9.478 inches long (PN 
84486S4). See note on page 2-46 in reas- 
sembly for buttstock assembly part usage. 




DOOR ASSEMBLY 
(LIFT OUT) 



Push down on plunger (5) with screwdriver and lift 
door assembly (6) out of butt plate (7) 



2-52 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



Remove straight pin (8) and separate hinge (9) and 
door assembly (61. 




b. CLEANING 



Clean all items. 



c. INSPECTION 



Inspect buttstock assembly for dents, cracks, and chips. Check for 
breaks and separation of material which could prevent proper func- 
tioning of v^eapon. 



CRITICAL AREA 
(SHADED) 





Under the follow/ing conditions, hairline cracks originating from buttplate end of buttstock are acceptable. No 
chipped away material is allowed. 

ID One hairline crack, not to exceed one inch in length, per side of buttstock. 

(2J Two additional hairline cracks up to .22 inch in length, per side of buttstock. 

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

Buttstocks with unauthorized markings stamped into their surfaces will be replaced. Unauthorized markings, 
scratched, etched, carved, etc, are acceptable if they do not extend into the fiber of the buttstock which may 
weaken it. These marks may lie at any location on the buttstock. 

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

Visually inspect all other parts for unserviceable or missing parts. Replace defective or missing parts. 



2-53 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



2-21. BUTTSTOCK ASSEMBLY (CONT), 



d. REPAIR 



Replace all authorized unserviceable items. Unserviceable items are those items which are damaged. 



e. LUBRICATION 



Lubricate all metal components with CLP, LSA, or LAW (p 2-22). 



f. REASSEMBLY 



1 



Position hinge (1) on door assembly (2) and install 
straight, pin (3). 




2 

Install door assennbly (2) into butt plate (4) and 
press plunger (5) to lock. 


/ . 


k\ 


\\ \ v 


W .A.^^5^^Ul 


^^^^^^^^ 


d) ^^"^^i^ 


© 





Position butt plate group (6) and rear siing swivel 
(7) to the buttstock (8) and secure with self-locking 
screw (9). 

NOTE 



See l page 2-50J reassembly, for reassem- 
bly of buttstock assembly to lower re 
ceiver. 10.103 inches long (PN 9349126) 
9.478 inches long (PN 8448654) 




2-54 



ARMY TM 9-1005-249-23&P 

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COAST GUARD COMDTINST M8370.9 



2 22. MAJOR COMPONENTS OF M16/M16A1 RIFLE. 



This task covers: 




a. Reassembly 


G. Stowage 


b. Inspection 




INITIAL SETUP 




Applicablo Configuration 


General Safety Instructions 


M16/M16A1 Rifle 


To avoid injury to eyes, use care when removing 




and installing spring-loaded parts. 


Reference 


Do not interchange bolt assemblies from one 


TM 9-1005-249-10 (operator's manual) 


weapon to another. Doing so may result in injury 




to, or death of, personnel. 


Equipment Condition 


Do not keep live ammunition near the work area. 


Weapon disassembled into major components 





a. REASSEMBLY 



NOTE 
Only direct support maintenance is authorized to restamp the serial number. 




Refer to operator's manual and install lower receiver and extension assembly (1), upper receiver and barrel assem- 
bly 12), charging handle assembly (31, bolt carrier assembly (4), small arms sling (5), and cartridge magazine (6). 



2-55 



ARMY TM 9-1005-249-23&P 
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2-22. MAJOR COMPONENTS OF M16/M16A1 RIFLE (CONT), 



b. INSPECTION 



Perform the following function tests 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. Leave hammer in cocked position. Do not pull trigger. 

WARNING 

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

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

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

NOTE 

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

4. Hold trigger to the rear, charge weapon, and release the trigger with a slow, smooth motion, without hesita- 
tions or stops, until the trigger is fully forward (an audible click should be heard). Hammer should not fall. 

5. Repeat the above selector lever SEMt 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 it to direct support 
maintenance for repair. 

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

7. Hold trigger to the rear, charge weapon, and release trigger. Pull trigger. Hammer should not fall. Automatic 
sear should have released hammer while holding trigger in the pulled position before releasing and pulling the 
trigger. 

8. With hammer in the forward position, attempt to place the selector lever in SAFE position. If the selector lever 
can be placed on SAFE by finger/thumb pressure, evacuate the rifle to direct support maintenance for repair. 

9. If weapon fails any of the above tests, evacuate to direct support. 



c. STOWAGE 



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

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 rifle in rack. 



2-56 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

CHAPTER 3 
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS 
CHAPTER OVERVIEW 

IChapter 3 I contains information and instructions to help keep the weapon In good repair. This chapter contains: 

a. Repair Parts, Special Tools, TMDE, and Support Equipment 

b. Service Upon Receipt 

c. Troubleshooting 

d. Decontamination of Rifles and Shop Area 

e. Maintenance Procedures for the M16 and M16A1 Rifle 

f. Preembarkation Inspection of Materiel in Units Alerted 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 and Coast Guard users must maintain the fol- 
lowing common tools: 



Flat tip screwdriver 
Socket wrench handle and 

socket head screw socket 

wrench 
Vise jaw caps 
Machinist's vise 
Solid center punch 
Hammer 



Combination wrench 
(2) eight-inch adjustable 

wrenches 
Flat file 

Ballpeen hammer 
Trigger Pull Test Fixture 

Rod & Weights 



5/64-Inch drive pin punch 

Retaining ring pliers 

1 /8-inch drive pin punch 

Torque wrench 

1 /1 6-inch drive pin punch 

3/32-1 nch drive pin punch 



I 



3-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT. Special tools required for direct support are listed in ap- 

I pendix "c] and fabricated tools are listed and illustrated ir i appendix El 



3-3. REPAIR PARTS. Repair parts are listed and illustrated in l appendix CI 

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 at the bot- 
tom o > page 3-39L If these parts are interchanged, the weapon must be checked/inspected 
as depicted in | paragraph 3-1 o7| 3-11, and 3-13. While performing these checks/inspec- 
tions pay special attention to the headspace requirements depicted on I pages 3-381 and 
3-39. 



Section II. SERVICE UPON RECEIPT 
3-4. GENERAL. 

a. Inspect the weapon for damage incurred during shipment. If the equipment has been damaged, report the dam- 
age on SF Form 364, Report of Discrepancy (ROD). 

b. Check the weapon against the packing slip to see if the shipment is complete. Report all discrepancies In accord- 
ance with the instructions in DA PAM 738-750. 

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

d. Check to see if all MWOs have been applied. 



3-1 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

3-5. SERVICE UPON RECEIPT OF MATERIEL. Refer to the following table. 

SERVICE UPON RECEIPT - M16/M16A1 RIFLE 



LOCATION 



ITEM 



ACTION 



REMARKS 



M16, M16A1 Rifle 



Charging handle 



Clear the weapon. 



Refer to TM 9-1005- 
249-10 (Operator's 
Manual) 



WARNJNa 



To avoid injury to eye, use care when removing and installing spring-loaded parts 

Remove. 



Bolt carrier assembly 
and bolt assembly 

All components 



Bolt carrier assembly 
and bolt assembly 



Cartridge magazine 



Visually inspect for proper assem- 
bly, damage, or for missing parts. 

Clean and lubricate (see p 2-22). 

Reassemble. 

Hand function to assure proper 
operation. 

Insert empty magazine and pull 
the bolt to the rear. Check maga- 
zine for positive retention, and 
check functioning of bolt catch by 
assuring that bolt locks to the rear 
with empty magazine inserted. 



Refer to Operator's 
Manual 

Refer to Operator's 
Manual 



Refer to Operator's 
Manual 



Refer to Operator's 
Manual 



Section III. TROUBLESHOOTING 



3-6. GENERAL. 



a. This section contains troubleshooting information for locating and correcting most of the operating troubles which 
may develop in the 5.56mm Rifle M16 and M16A1. Each malfunction for the individual component, unit, or system is 
followed by a list of tests or inspections which will help you to determine the corrective actions to take. You should 
perform the tests/inspections and corrective actions in the order listed. 

b. This manual cannot list ail 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 for maintenance 
instructions on each major assembly. 

3-7. TROUBLESHOOTING PROCEDURES. Refer to troubleshooting table for malfunctions, tests, and corrective ac- 
tions. The symptom index is provided for a quick reference of symptoms covered in the table. 



3-2 



ARMY TM 9-1005- 249-2 3&P 

AIR FORCE TO 11V F3^ 5-24 

COAST GUARD COMDTINST M8370.9 



SYMPTOM INDEX 



Troubleshooting 

Procedures 

Page 



Failure of magazine to lock in weapon i 3-41 

Fail ure to feed | 3-41 

Failure to ciiamber i 3-41 

Failure to lock i 3-41 

Failure to fire | 3-51 

Failure to unlock | 3-51 

Failure to extract | 3-61 

Failure to eject 13-61 

Failure to cock 13-61 

Short recoil HTTI 

Weapon cannot be zeroed 13-81 

Failure to cycle with selector lever set on AUTO 13-81 

Fires when trigger is released with selector lever on SEMI, or fires two or more rounds in 

SEMI selector position (Doubling) 13-91 

Fires with selector lever on SAFE |3-9| 

Bolt fails to lock to rear after firing last round 13-91 



ARMY TM 9-1005-249-23&P 
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TROUBLESHOOTING 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 




1. FAILURE OF MAGAZINE TO LOCK IN WEAPON. 

Step 1. Dirty or corroded magazine catch (1). 

Disassemble and clean. 
Step 2. Defective magazine catch spring (2). 

Replace spring (2). 
Step 3. Worn or broken magazine catch (1). 

Replace magazine catch (1). 

2. FAILURE TO FEED. 

Step 1. Magazine catch spring (1 ) weak or broken. 

Replace magazine catch spring (1). 
Step 2. Magazine catch (2) broken or defective. 

Replace magazine catch (2). 
Step 3. Short recoil. 

Refer to l page 3n 

3. FAILURE TO CHAMBER. 

Obstruction in bore/chamber. 

Remove obstruction. If unable to remove obstruction, rebarrel 

4. FAILURE TO LOCK. 

Step 1. Damaged bolt carrier key (1). 

Repair or replace bolt carrier key (1) and check alignment. 
Step 2. Loose screws (2) on bolt carrier key (1). 




{p. 3-28). 



Disassemble and repair (p 3-19). 
Reassemble using new screws. 




Step 3. Bent gas tube (3) 




Adjust by bending tube in area of handguards. 
Replace gas tube (3) and check alignment. 



3-4 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-24 

COAST GUARD COMDTINST M8370.9 



TROUBLSHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



5. FAILURE TO FIRE. 

Step 1. Broken hammer (1). 

Replace hammer (1). 
Step 2. Weak or broken hammer spring (2). 

Replace spring (2). 
Step 3. Hammer spring (2) improperly assembled. 

Reassemble correctly (p 3-62). 
Step 4. Selector lever (3) frozen on SAFE position. 

Disassemble and clean. 

step 5. Broken firing pin (4) or firing pin does not 
meet gage protrusion requirement. 

Replace. 

Step 6. Damaged, dirty, or corroded spring (5) and 
detent (6). 

Clean and/or replace if necessary. 



6. FAILURE TO UNLOCK. 

Step 1. Burred locking lugs (1) cm bolt assembly (2). 

Remove burrs. 
Step 2. Burred locking lugs (3) on barrel extension. 

Remove burrs. 
Step 3. See short recoil (p 3-70. 
Step 4. Broken bolt assembly (2). 

Replace bolt assembly (2). 




3-5 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



7. FAILURE TO EXTRACT. 

Badly pitted chamber (1). 

Replace rifle barrel assembly. 

8. FAILURE TO EJECT. 

See short recoil (p 3-7). 

9. FAILURE TO COCK. 

Step 1. Worn or broken trigger nose (1) or 
trigger spring (2). 

Replace trigger (3) or defective 
trigger spring (2). 

Step 2. Worn or broken hammer trigger notch 

(4) 

Replace hammer (5). 

Step 3. Worn or broken hammer disconnector 
hook (6). 

Replace hammer (5). 

Step 4. Worn or broken hammer automatic 
sear hook (7). 

Replace hammer (5]. 

Step 5. Worn or broken disconnector hook (8). 

Replace disconnector (9). 

Step 6. Weak broken, or missing trigger 
spring (10) 

Replace spring (10). 

Step 7. Worn, broken, or missing automatic 
sear(1 1 ). 

Replace automatic sear (11) 

Step 8. Weak or broken automatic sear spring 
(1 2). 

Replace automatic sear (11). 

Step 9. Automatic sear spring (12) incorrectly 
assembled in receiver. 

Remove automatic sear assembly (11 
and install correctly (p 3-59). 




3-6 



ARMY TM 9-1005-249-23&P 

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COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING {CONT] 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



10. SHORT RECOIL. 

Step 1. Improper gap, space or worn, missing, or broken bolt rings (1). 
Replace bolt rings and stagger gaps. 




Step 2, Broken or bent gas tube (2). 

Adjust by bending in area of handguards or replace gas tube. 

1 




Step 3. Gas tube spring pin (3) missing from front sight (4). 

Replace spring pin (3). 
Step 4. Partially plugged gas system because of carbon buildup in the gas tube (2). 

Replaee gas tube |2), 




d^^-^fW^;,^ 



WARNING 

When using PC-1 1 1, avoid skin contact. If h comes in contact with the skin, wash 
off thoroyghiy with running water. Using a good lanolin base cream after exposure 

is helpful. Using rubber gloves is recommended. /^ 

Step 5. Carbon busfdyp m barrel gas port 15). ^- 

Remove carbon buildup by soaking 
m P-C-1 1 1 (item 8 J app D)) Wea r 
rubber gloves (item 16j app DK 




3-7 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
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TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 



11. WEAPON CANNOT BE ZEROED 

Step 1. Bent or bulged rifle barrel (1). 

Replace rifle barrel 
assembly (1 ). 




Step 2. Barrel assembly out of alignment with rear sight on upper receiver 

Align barrel and upper receiver (p 3-33). 
Step 3. Corroded front (2) or rear (3) sights. 

Disassemble, clean, and lubricate. 



(7)- ^ 




( 3y™™""- — --**'^^ 




12. FAILURE TO CYCLE WITH SELECTOR LEVER SET ON AUTO 
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. 

See malfunction 11. 



dX^^ 




3-8 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



TROUBLESHOOTING (CONT) 



MALFUNCTION 

TEST OR INSPECTION 

CORRECTIVE ACTION 




13. FIRES WHEN TRIGGER IS RELEASED WITH SELECTOR LEVER ON SEMI, OR FIRES TWO OR MORE ROUNDS IN 
SEMI SELECTOR POSITION (DOUBLING). 

Step 1. Defective disconnector (1). 

Replace disconnector (1). 

step 2. Worn or broken hammer trigger notch (2). 

Worn or broken hammer disconnector notch (3). 

Replace firing hammer (4). 
step 3. Worn or broken trigger nose (5). 

Replace trigger (6). 
Step 4. Worn trigger or hammer pin hole. Gage trigger and hammer pin holes. 

If gage 12006472 enters any of the four holes, replace weapon (p 3-57). 

14. FIRES WITH SELECTOR LEVER ON SAFE. 

Step 1. Defective selector lever (1). 

Replace selector lever (1). 
Step 2. Worn or broken trigger (rear portion (2). 

Replace trigger (3). 

15. BOLT FAILS TO LOCK TO REAR AFTER FIRING LAST ROUND. 

Step 1. Broken bolt catch (1). 

Replace bolt catch (1). 
Step 2. Weak or broken bolt catch spring (2). 

Replace bolt catch spring (2). 
Step 3. Restricted movement of bolt catch (1). 

Disassemble and clean. 




Section IV. DECONTAMINATION OF RIFLES AND SHOP AREA 
3-8. DECONTAMINATION OF SIGHTS ACTIVATED WITH TRITIUM (H3). Refer t FOTapteFl Section V for procedures. 



3-9 



ARMY TM 9-1005-249-23&P 
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Section V. MAINTENANCE PROCEDURES FOR THE M16 AND M16A1 RIFLE 



3-9. MAJOR COMPONENTS OF M16 AND M16A1 RIFLE. 



This task covers disassembly. 



INITIAL SETUP 

Applicable Configuration 
M16/M16A1 Rifle 

Tools 
Small Arms Repairman Tool Kit 
SC 51 80-95-CL-A07 (1 9204) 

Reference 
TM 9-1005 ^_9_^1_ 0_ (operator's manual) 

Equipment Condition 
Weapon assembled 



General Safety Instructions 

Before starting an inspection, be sure to clear the 

weapon. Do not actuate 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. 

WARNING 



A^4 



Before starting an inspection on a weapon equipped 
with a low light level sight, check for damage to 
i tho l ow li g ht level sight. See procedures listed on 
page 2-21. 



DISASSEMBLY 



a. Refer to TM 9-1005-249-10. 

b. Remove cartridge magazine (1), small arms 
sling (2), bolt carrier assembly (3), charging 
handle (41, upper receiver and barrel 
assembly (5), and lower receiver and exten- 
sion assembly (6). 




M16A1 



3-10 



3-10. BOLT CARRIER ASSEMBLY. 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



This task covers: 








a. Disassembly 




d. Repair 




b. Inspection 




e. Reassembly 




c. Test 








INITIAL SETUP 








Applicable Configuration 




Materials/Parts 




M16/M16A1 Rifle 
Test Equipment 




Cleaner, lubricant and preservative (CLP) 


(item 9, 


lapp V^ 
Lubricating oil, weapons (LAW) (item 20, 


kpp Db 


Tool and Gage Set 8426685 


Lubricating oil, weapons (LSA) (item 21, 


bDD Db 










Tools 








Small Arms Repairman 


Tool Kit 


Equipment Condition 




SC 5180-95-CL-A07 


(19204) 


Page Condition Description 

3-10 Bolt carrier assembly removed 




a. DISASSEMBLY 









1. Remove firing pin retaining pin (1). 

2. Tip key and bolt carrier assembly (2) allow- 
ing firing pin (3) to drop out. Catch the fir- 
ing pin. 

3. Rotate bolt cam pin (4) 1/4 turn and lift 
straight up to remove. 

4. Remove bolt assembly (5) from key and bolt 
carrier assembly (2). 




3-11 



ARMY TM 9-1005-249-23&P 

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3-10. BOLT CARRIER ASSEMBLY (CONT). 



b. INSPECTION 



[i I In p e c 1 h II c ai [ In nut \\] [\] fn h ns , na c t s , 
r n \ . 1 H n Id M H o I g n In ! . 

[b I V Is n II) li s p M I lie c nil! i n d h f s cm s {\] fn 
Im s M ! s s n d propel s N i h g n s h i i b e In . 



I [ 



H n 1 1 ll! I p t 1o n In q i e If Ih n ! is n 
Im s ! HI g H lie s e le « s li d It i te d If lie 
s ta Mn f m n i s . 

S n f n e " i ' n n 1 n 1 i H I u I e d I s I e r II e n d i 
d i I a g t w I l[ I 1^ p nis p n i lie lis i . 




IRTACL A 



(O) (O) 3 ^ SURFACE A (0> <(0) _} ^ SURFACE A (q) (o) } t 



FItiU RFFIACEMEN7 STAKilVG 



ORIGINAl SIAKING 



0?b MAX 
4 P.ACES 



T~"f^ 



I E 



'^A V-'A Y^-% 



n e I e n ! I e lis e i d b HI c a i lie r s i ^ f le Id t d m e e p n s . s i m t Mil e I 1 1 i e j li 1 e d 

! I le lin s y I f H e flushes i n d \\i\ \ \\\ p h i s p I a le t o i lin f . E oil Mns h e s e i e 

n c e p 1 e I I i y n d n i n 1 e 1 1 d p e r a 1 1 m i I 1 1 q i i r e i e H s n d I e r i i s 1 1 1 1 1 i n s . M n p I i 1 e - 

n 1 le d loll t n rle rs \\\ le q uli e d U i d Ills le n I n n I a I nils. CI re n np h le d I e II 

M I lie IS e le e n t p li Me fn d li Is In a I u n e n I U y nls n d li i Inh g t e tin y i lis . 
C I 1 1 n e 'p la It d end p I o s p I i le -n i le d bill e s s t n I lit s . bell t e 1 1 le i i s s t ^ b lie s , n d 

re p lir p i i Is fo i II t s t e s s e di I lie s i \\ be Inlt i n In d In \\\ n n I in lin , i III lit 
U IIm In j e n e p He n 

P I D s p I 1 le -n 1 le d bell t e 1 1 It i s ne rt q y lie d U i all d e p h f i b le a H d e p Id ) h g y nls . 
C h I D Di e -p h It d bell n riie is a le a e e e p le b le U i n H t p le f i b It e i d Ira inn g n n ft r 
y nils . 



n p e e 1 \\\\\\ pin \\\ lip fe i p n p t r n He y i . In s p e t 
II p Iflli g . i e 1 I . \\i b n IS . Mis i i ( t a i li i le i (4 
s p t n Is s II It . n e p h [ t If n s i i vli i i b It . 




] -1 \ 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



Prior to reassembly, insert bolt assembly (5) in to 
bolt carrier assembly (1), and exercise bolt in and out 
of bolt carrier assembly. Check for binding. 



OUT 




C h e c I b It a s s e i Mf (S ) fo I p 10 p e I fit. I y I n b o It c a i- 
rier assembly (1) and suspend so the bolt assembly is 
pointed down. 

NOTE 

The bolt assembly (5) must not drop out. 
If weight of bolt assembly allows it to drop 
out of carrier assembly, replace bolt rings 
(P 3-18). 




c. TEST 



1. Insert firing pin (2) through bolt assembly (3). 

2. Position firing pin protrusion gage (1) PN 


(^ 


^ 




- 




XD 


\^" 




7799735 to check for proper firing pin (2) protru- 


kj 


S/^^^SK 






^ y" 


<^^-^ 


sion (minimum 0.028- maximum 0.036). 


i 


^^^Wa^ 




d— -* 


t/ 




NOTE 


d 


\ 


f£^J^^Sg 


^ 


^ 


■^ 


Firing pin should touch the gage on 




^y 




\ 


J 




minimum but should not touch on 




C^j 




' ^ 


f5C 


■^ 


maximum. 








I 


^V^ 


r 


3. Replace a defective firing pin. 








\ 







3-13 



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3-10. BOLT CARRIER ASSEMBLY (CONT). 



d. REPAIR 



1. 


Replace all authorized unserviceable items. 




NOTE 




Be sure to retest a replaced firing pin, key and bolt carrier assembly, bolt assembly, or 




bolt carrier assembly. 


2. 


Lubricate all metal parts using CLP, LSA, or, LAW (see p 2-22). 



e. REASSEMBLY 




WARNING 

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

NOTE 

Before installing bolt assembly, check to see that the ring gaps are staggered to prevent 
loss of gas pressure. 

1. Install bolt assembly (1) into key and bolt carrier assembly (2). 

2. Install bolt cam pin (3) and rotate 1/4 turn to secure bolt assembly ( 1). 

3. Hold key and bolt carrier assembly (2) with bolt assembly ( 1 ) down and drop in firing pin (4). 

4. Install firing pin retaining pin (5) from left side only to ensure proper installation. Check for proper installation by 
attempting to shake out firing pin. 



3-14 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-11. BOLT ASSEMBLY. 



This task covers: 






a. Disassembly 




d. Clean/Lubricate 


b. Inspection/Repair 




e. Reassembly 


c. Test 






INITIAL SETUP 






Applicable Configuration 




Materials/Parts 


M16/M16A1 Rifle 




Cleaner, Lubricant and Preservative (CLP) (item 9, 


lapp 0} 


Test Equipment 




Lubricating oil, weapon (LAW) 


Tool and Gage Set 8426685 


Lubricating oil, weapon (LSA) 


Gloves, protective (item 16Japp U) 


Tools 




Penetrant kit (item 23, ^pp LI) 


Small Arms Repairman 


Tool Kit 


Kaq, wiping (nem ^4, |app p) 


SC 5180-95-CL-A07 


(19204) 


Equipment Condition 

Page Condition Description 

3-10 Bolt carrier assembly removed 






3-11 Bolt assembly removed 



a. DISASSEMBLY 



NOTE 

Do not remove bolt rings unless they require re- 
placement. 

Using flat tip screwdriver (1) remove the three bolt rings (2) 
from the bolt (3). 




b. INSPECTION/REPAIR 




3-15 



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3-11. BOLT ASSEMBLY (CONT). 



b. inspection/REPAIR (CONT). 



Inspect bolt ( 1 ) for pits, burrs, and wear as follows: 

(a) Bolt faces with a cluster of pits which are touching or 
tightly grouped, covering an area measuring approx- 
imately 1/8 inch across, will be rejected and replaced. 

(b) Bolts which contain individual pits or a scattered pat- 
tern will not be cause for rejection. 

(c) Bolts that contain pits extending into the firing pin 
hole will not be rejected unless firing pin hole gaging 
check determines excess wear. 

(d) Rings on the bolt face (machine tool marks), grooves, 
or ridges less than approximately 0.010 inch will not 
be cause for rejection. 



CLUSTER OF 
PITS 




NOT ACCEPTABLE 



ACCEPTABLE 



H p E c t h II |1 I fn c in h m p e c Is llf h Ih e U c I; In g lu g s i 
:li e h c I h 3 lu g s h s e , n d II ! n n pin I o le i \n . Ij s e 
] In I llg h il n 3 Ih b le ; o tl sn Is s , y n a g In s H n n oi! 
in n lip Ifk a tin n y n 3 p n Mr3 n I III. 




LOCKING 
LUG 



CAM PIN 
HOLE 



3-16 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST IUI8370.9 



WARNING 

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

Use penetrant kit as follows: 

The area to be inspected must be clean, free of oil, etc. 
Spray a small amount of remover on the area to be in- 
spected, let dry, and wipe off with a wiping rag. 




CAM PIN 
HOLE 



LOCKING 
LUG 



I } \i} p M t Itn I (n If M n g h lo u M !h mm | n th a in 

I the h It |1 } to b e in p m tH . 

1 } \ij d n t Id p n n n the p n e tin t n d It t the d m e U p ei 
i nl. C in i j H III be IH In tH b f a c I n g e In n In » I ne 
tine Is 3 n n I . II tine ne nn i s , tb t n i p n n I is 
y n s e rv In i b le . 

N I [Ion 1 tte Hlo n to tie nt i wine th U o Un g h g s i t e I 
tie b H ) . 

II tl e It m H ni c i n s p ra ) le m o n i on tie ne a , It t d i) , 
n d ( Ip t tl ( Itl 3 i Ip h g [ 1 9 . Oil tie 3 it i to p it n n t 
in s lo 3 . 

n t p li e boll 1 s s e I b I) II h II (1 j is d e te t tin . 




CAM PIN 
HOLE 



T E 



Replacement of the bolt assembly will require that the headspace be tested {p 3-38, 
TEST). 



3-17 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3-11. BOLT ASSEMBLY (CONT). 



c. TEST 



NOTE 

Do not force the gage into bolt assembly. 

Inspect bolt (1 ) for elongated or oversized firing pin hole 
using special no-go plug gage (2) PN 12620101. 

NOTE 

Bolts with firing pin hoes which permit the 
special no-go plug gage to fully penetrate at 
any position on the circumference will be re- 
jected and replaced. 




d. CLEAN/LUBRICATE 



Clean all items (operator's manual). Remove carbon deposits with CLP or RBC. Lubricate all items with a light coat 
of CLP, LSA, or LAW. 



e. REASSEMBLY 



Install the three bolt rings (1) one at a time onto the 
bolt (2) using care not to bend them. Stagger the bolt 
ring gaps to prevent loss of gas pressure. 

NOTE 

Make certain ring gaps are staggered to pre- 
vent loss of gas pressure. 




3-18 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-12. KEY AND BOLT CARRIER ASSEMBLY 



This task covers: 












a. Disassembly 










c. Reassembly 


b. Repair 












INITIAL SETUP 












Applicable Configuration 










Equipment Condition 


M16/M16A1 Rifle 










Page Condition Description 

3-10 Key and Bolt Carrier Assembly removed 


Tools 










3-11 Bolt assembly removed 


Field Maintenance Basic 


Less Power 


Small 


Arms 




Shop Set SC 4933-95-CL-A11 


(19204) 






Small Arms Repairman Tool Kit 










SC 5180-95-CL-A07 { 


19204) 










Key tool jfjg E-3j tpp_EJ 



a. DISASSEMBLY 



NOTE 

Do not disassemble the key and bolt carrier 
assembly unless the bolt carrier key or bolt car- 
rier is defective. New screws must be used if 
disassembled. 

1. Using socket wrench handle and socket head screw 

socket wrench, remove the carrier and key screws (1). 

2, Remove bolt carrier key (2) from bolt carrier (3). 




3-19 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3-12. KEY AND BOLT CARRIER ASSEMBLY (CONT). 



b. REPAIR 



NOTE 
Do not reuse old screws. New screws must be used at assembly. 
Repair by cleaning mating surfaces, replacing, properly torquing, and restaking carrier and key screws 



c. REASSEMBLY 



(a] If disassembled, install and position bolt carrier key 
(1) on bolt carrier (2). 

(b) Install two carrier and key screws (3). Always use 
new screws. 




P In ! h It c niier in i n lins t's ns e y s in g vise jn n p s . 

NOTE 

Do not reuse old screws. 

Use a socket head screw wrench attachment and torque 
wrench to torque the carrier and key screws (3) to 35 to 
40 inch-pounds. 




3-20 



ARMY TM 9-1005-249=23&P 

AIR FORCET0 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3 



i T 



The method of staking will be accomplished 
as pictured below. 

Use solid center punch, and hand hammer to stake the 
two carrier and key screws (2) in three places. 




S ta h c a I lin a H I e f s c le w s 



NOTE 



A maximum of 0.025 inch protrusion in an upward direction is permissible. 



SURFACE A 



© ©33 



0.025 MAX 
4 PLACES 



^ 



^^^ 



FIELD REPLACEMENT STAKING 



NOTE 



If the bolt carrier key is replaced, three to eight rounds of blank or ball ammunition 
must be fired to insure a seal is created. Manual operation of the rifle may be required. 
If blank ammunition Is utilized, M15A2 Blank firing Attachment must be adapted. 



3-21 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

3-13. UPPER RECEIVER AND BARREL ASSEMBLY. 



This task covers: 

a. Disassembly 

b. Inspection/Cleaning 

c. Repair 




d. Reassembly 

e. Test 


INITIAL SETUP 

Applicable Configuration 
M 16/M16A1 Rifle 

Test Equipment 

Tool and Gage Set 8426685 

Tools 

Small Arms Repairman Tool Kit 

SC 5180-95-CL-AO7 { 19204) 
Field Maintenance Basic Less Power Sma 

Shop Set SC 4933-95-CL-A11 (19204 

Materials/Parts 
Carbon removing compound {P-C-111 ) (i 

1 apP D) 
Cleaner, lubricant and preservative (CLP) 


II Arms 

em 8, 
(item 9, 
n 11, 


Equipment Condition 

Page Condition Description 
2-35 Hand guards removed 

3-10 Upper receiver and barrel assembly removed 
from tower receiver and extension assembly. 

General Safety Instructions 

To avoid injury to your eyes, use care when removing 

and installing spring-loaded parts. 
When using solid film lubricant or dichloromethane, be 

sure the area is well ventilated. 
When using P-C-111, avoid skin contact. If P-C-111 

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 

recommended. 
Dry cleaning solvent is flammable and toxic and 

should be used in a well-ventiliated area. The use of 

rubber gloves is necessary to protect the skin when 

washing rifle parts. 

WARNING 

Upper receiver and barrel assembly may be 
equipped with low light level front and rear sights. 
The front sight contains radioactive material. If so 
equipped, do not insert metal objects into the post 
slot or otherwise treat roughly to cause breakage 
of the radioactive element. 


lapp L)| 
Cleaning compound, rifle bore (RBC) (itei 
lapp D\ 


Cloth, abrasive (item 12. Add D\ 


Uichloromethane. technical (item 14. ^pp 


16, 


Dry cleaninq solvent (item 15. kpp D\ 
Gloves, chemical and oil protective (item 


1 app DD 

Grease, molybdenum disulfide (item 17, 
Lubricant, solid film (item 19. App UI 
Lubricating oil, weapons (LAW) (item 20, 
Lubricating oil, weapons (LSA) (item 21, 
Pan, wash (item 22, fpp Df 


ipp D| 


*PP D) 
NpP Dt 


Sealing compound (item 26. fapp b\ 

References 
FM 23-9 


|TM 9-1005-249-10 floperator's manual) 



3-22 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11 W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




a. DISASSEMBLY 



1 



WARNING 

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

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

When using P-C-1 11, avoid skin contact. If P-C-111 comes in contact with the skin, wash 
thoroughly with running water. Using a good lanolin base cream after exposure to com- 
pound is helpful. Using gloves and protective equipment is recommended. 



AA 



Upper receiver and barrel assembly may be equipped with low light level front and rear 
sights. The front sight contains radioactive material. If so equipped, do not insert metal 
objects into the post slot or otherwise treat roughly to cause breakage of the radioactive 
element. 





CAUTION 

When using the barrel removal fixture, always Insert the barrel from the same direction 
to avoid damage to the fixture. 

(a) Position upper receiver and barrel assembly (1) in barrel removal fixture and secure both in machinist's vise. 

{b} Using combination wrench (2) and 1/2 inch-drive handle, remove flash suppressor (3). 

NOTE 

There are two types of flash suppressors. The earliest design Is open ended with three 
prongs. The latest Is a closed-end design and Is the only authorized repair part. 

All M 16A1 rifles assigned to divisional combat units must be equipped with the closed 
end flash suppressor. M 16A1 rifles assigned to noncombat unit and training center units 
may be equipped with either the open or closed end type flash suppressor. If the old type 

flash suppressor Is removed. It must be replaced with the new type flash suppressor. 



3-23 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-13. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



a. DISASSEMBLY (CONT). , 



(a) Remove lockwasher. 

(b) Remove upper receiver and barrel assembly (1) 
from barrel remover fixture and vise. 




Using ball pen li a i oi e r a H I li \ h c li - d i a m e t e r d r i u 
pin p y n c li , re oi m e spring p io (S | (n He li retains the gas 
tube) iro 01 the ir a n t s ig li t a a a e oi b if (S |' 





Slide gas tube (7 ) i a c K into 
a H le m V e gas tube (7 ), 



y n ^ ' '^ ' ' iv ' ' M M^i c ie a I lio n t s ig h t a s s e m b if (G ), lb e n lilt s lig li tif , p y II Io id a id 



3-24 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



(a) 




Place upper receiver and barrel assembly (1) into barrel removal fixture and clamp into machinist's vise. 

CAUTION 

When using the barrel removal fixture, always insert the barrel from the same direction 
to avoid damage to the fixture. 

NOTE 



Be sure all three drive pins on combination wrench are engaged with barrel nut assembly 
(9). Wrench must be pushed toward upper receiver (8) to compress the slip ring spring 
in barrel nut assembly (9). 

(b) Using socket wrench handle and combination wrench (2), loosen barrel nut assembly (9). 




(a) Separate upper receiver assembly (8) from barrel assembly (10). 

(b) Remove rifle barrel assembly (10) from vise and barrel removal fixture. 



3-25 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-13. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



a, ni^A^^FMRlY ICQMJ) 




{i] ^ i t n n [ t h ini j i ii j [\ 1 | y s ii g 1 1 ta ini j i ii j p lie is . 

(b) Remove slip ring spring (12) and handguard slip ring (13). 

(c) Do not remove barrel nut (14) from rifle barrel assembly (10). 



b. INSPECTION/CLEANING 



1 

(a) 


Inspect gas tube 


for 


cracks and 


deformities. 


RepI 


ace 


if defective. 
















(b) 


Use P-C-111 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. 












(c) 


Visually 


inspect 


all 


other parts 


for unserviceable 


or 


missing 


parts. 


Replace 


defective 


or 


missing 


parts. 





3-26 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



[i ] In s p n t lifU b o le n d In t li in g lugs fo i b u iii , 
t in h , lu j t, b u Ig e s , n d pits, 

(] ) Fits no Md e I th n i In d o i g id o v e n d no 
1 n g 1 t h n 3 19 Inch no H I o v o d In t h o b o i o , 

(!) L n d j th s t 3 p p n d nil b lu o duo to coating o t 
gliding m o tH tio m p lo jo c tllo s no Hlo v a b lo , 

(3 ) D tin Ito If iln g d b o lo ! o i b o lo i iln g o d n ttl- 
ciently to bulge the outside surface of the barrel 
are cause for rejection. Replace rifle barrel 
assembly if defective. 

NOTE 



Chamber may be inspected with or 
without upper receiver assembled to 
the barrel assembly. 

(b) Inspect chamber using reflector tool 1) and 
flashlight (2). 

Pits 1/8 inch in length are cause for rejection. 
Replace rifle barrel assembly if defective. 




- CUTAWAY VIEW 




NOT ACCEPTABLE 




ACCEPTABLE 



3-27 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3-13. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



c. REPAIR 



1. Replace all authorized unserviceable items. 

2. Straighten bent front sight guards (1) as follows: 

CAUTION 

Remove spring before heating. (Heat will 
damage spring. ) The sight post and plunger 
may be reused unless damaged. 

(a) Remove front sight post, plunger, and spring 
(see p 2-38). 

(b) Place front sight base (2) in a bench vise. 

Use copper or brass caps (jaw inserts) on vise to 
prevent damage to sight base (2) during 
clamping. 

(c) Heat front sight guards (1) and bend with pliers. 
The front sight guards (1) should be put back as 
nearly as possible to the original position. Allow 
front sight housing to air cool. 

WARNING 



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

(d) Roughen any damaged surface of front sight 
guard with abrasive cloth and clean with dry 
cleaning solvent. Wear rubber gloves and use a 
wash pan to apply solvent. 

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. 



3-28 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3. Slightly bent barrels may be straightened as follows. 

(a) Check straightness using straightness gage (3) 8448202 (p 3-37). If the barrel fails the straightness test, 
and the gage remains in the barrel in the area of the front sight, 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. Insure 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 and the flash 
suppressor 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, remove the gage and replace the barrel 
assembly. 

(c) Place the barrel in a vise using appropriate protective jaws. Clamp the barrel between the front sight 
assembly and the flash suppressor approximately one inch from the front sight assembly. The 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. 




3-29 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3-13. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



c. REPAIR (CONT) 



(f) Remove the barrel from the vise and recheck 
straightness (step (a)). 

(9) 1^ 9396 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 barrel. 

(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 3-39). 



d. REASSEMBLY 




(a) Position barrel nut (1) by sliding it to the rear of barrel assembly (2) as far as possible. 

(b) Slide handguard slip ring (3) over barrel nut (1). 

[c) Press slip ring spring (4) from both sides and insert it into handguard slip ring (3). 

[d) Install retaining ring (5) against slip ring spring (4) using retaining ring pliers. Snap retaining ring (5) to barrel 
nut (I). 



3-30 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




CAUTION 

When using the barrel re- 
moval fixture, aiways insert 
the barrel from the same di- 
rection to avoid damage to 
the fixture. 



NOTE 



Wipe upper receiver tliread clean and ensure there are no burrs. Apply molybdenum 
disulfide grease to the threads before installation. This operation must be done in order 
to make later removal of the barrel easier. 

(3) Position riflebarrelassembly(2)with alignmentpin (6)up, Using barrel re movalflxtu re, clamp barrelassembly 
(2) in vise. 

(b) Align upper receiver assembly (7) using barrel alignment pin (6) and the slot in upper receiver assembly (7). In- 
stall over end of barrel assembly (2). 



(3) Engage tlireads of barrel nut assembly (8) with up- 
per receiver assem biy (7). 

(b) Using combination wrench (9) and torque wrench, 
torque barrel nut assembly (8) to 30 ft-lb. Torque is 
measured when both wrenches are used together. 

NOTE 



Two time torquing (three times total) pro- 
cedures provide for a better thread fit and 
prevents barrel nuts from becoming loose. Do 
not use the torque wrench for loosening. 

[c) Make certain all three drive pins on combination 
wrench are engaged with barrel nut assembly (8). 
Loosen and repeat torque operation. Then loosen 
the barrel nut again. 




3-31 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3-13. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



d. REASSEMBLY (CONT) 




VERTICAL 

TARGET 

LINE 




Loosen the vise and align the front sight assembly base (10) in a vertical position (use a vertical line on the wall to 
check this) then tighten vise to hold t-he barrel assembly (2) in that position. 




NOTE 



Upper receiver and barrel assembly may be equipped with low light level front and rear 
sights. The low light level front sight must be removed, shipped in its original container 
and reinstalled at unit maintenance. 

(a) With front sight assembly base (1 O) centered, view from the rear and rotate the upper receiver (7 'M' '' l^" 
to align rear sight to the same vertical line as front sight. 

NOTE 
Do not attempt to hold the upper receiver (7) with a pry bar; however, if the barrel assembly 
(2) turns in the holding fixture, a pry bar may be used in the front sight assembly base 
(10) to help prevent the barrel from turning in the holding fixture. Use care not to distort 
or bend front sight or retaining pins. 

(b) Torque the barrel nut assembly again to 30 ft-lb while maintaining sight alignment. The barrel nut may be 
tightened beyond 30 ft-lb to align the barrel nut serrations for gas tube clearance. Never loosen the barrel nut 
assembly (8) to align for gas tube clearance. 



3-32 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



n n in 

Do not torque over 80 ft-lb while tightening 
the barrel nut to next hole, to allow for 
proper alignment. 

(a) Align barrel nut assembly (8) with hole in the upper 
receiver assembly (7) using 1/8 inch drive pin 
punch. If necessary, tighten nut to next hole to 
allow proper alignment. 

(b) Remove drive pin punch from upper receiver and 
barrel assembly (11). Remove upper receiver and 
barrel assembly (1 1) from barrel remover fixture 
and vise. 





Slide gas tube (12) through the barrel nut assembly 
(8) and then slide forward inserting gas tube into 
hole in the front sight assembly base (10). 



8 




|i M lig n II ! hits i^ gas tube (12) and front sight 
assembly base (1 O). 

(b) Using ball peen hammer and 5/64-inch diame- 
ter drive pin punch, drive spring pin (13) into 
front sight assembly base (10) to secure gas 
tube (12). 



3-33 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-13. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



d. REASSEMBLY (CONT) 




c n I II 



When using the barrel removal fixture, 
always insert the barrel from the same 
direction to avoid damage to the fixture. 

(a) Install upper receiver and barrel assembly (11) into 
barrel removal fixture and vise. 

(b) Install lockwasher (14) and closed end flash sup- 
presser (15) on upper receiver and barrel assembly 
(11). 




10 




Torque flash suppressor (15) to 15-20 ft-lb using combination wrench (9) and torque wrench. Torque is 
measured when both wrenches are used together. 



3-34 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



11 

■ ■ NOTE 




® 


s« 


k 


Refer to Operator's Manual fc 
system" procedures for i 
handguards. 


r "buddy 
nstalling 


N 


V 


1 


1 


Install upper and lower handguards 


(16). 




{J- 


S 


r 






i 




3 



e. TEST 



1 



Determine the type of bore and chamber to be gaged. 

NOTE 

The following is the way to identify chromed barrels from unchromed barrels. 
Stampings on the barrel approximately one inch rearward from the flash suppressor 
are as follows 

(a) (SAK MP C) 5AK is the manufacturer's stamp, MP indicates magnetic partical 
inspection, C indicates chrome chamber only, or (C MP C) C = Colt Manufacturer, 
MP = magnetic partical inspection, and C = chrome chamber only. 

(b) Other markings which indicate chrome chamber only are "C" alone or "RUC" or 
"RNC" alone. A "C" stamped on the barrel between the rings of the front sight 
base also indicates chromed chamber only. 

(c) Markings the same as in (a) above with the last letter "B" indicate a fully chromed 
bore and chamber. 

(d) Other markings such as "CB" alone indicate a fully chromed chamber and bore. 

(e) The latest configuration is identified with the words "Chrome Bore" written out. 

(f) Barrel that does not meet the above criteria is non-chrome. 



H T E 

To insure proper operation of the gages, the barrel must be clean prior to performing 
the tests. 

The following information pertains to the gages required for the upper receiver and 
barrel assembly. 

(a) Barrel erosion gage, P/N 7799792, is to be used to check barrels that are not 
chromed. Instructions for its use are on the tag attached to the gage. The first 
line from the end of the gage is the reject line. The second line is no longer used. 

(b) Barrel erosion gage, P/N 8448496, is to be used only on fully chromed barrels. 
Instructions for its use are on the tag attached to the gage. 

(c) The muzzle erosion gage, P/N 8446677, is used on the unchromed barrel only. 
It is not required for use on chromed bore barrels. Instructions on its use are on 
the tag attached to the gage. 

(d) The bore straightness gage, P/N 8448202, is required for use on all barrels. The 
gage must pass through the barrel without force. 



3-35 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3- 13. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



e. TEST (CONT) 




REJECTION MARK 



L 



GAGE, BARREL 
EROSION 



OLD REJECT MARK 
NO LONGER USED 



(a) To check erosion in an UNCHROMED barrel only, in- 
sert barrel erosion gage (1 ) PN 7799792 into breech 
end of upper receiver (2). 

(b) Gage must not go beyond rejection mark when 
viewed from front edge of magazine well (3) in up 
per receiver (2). 

NOTE 

If barrel erosion gage goes past the rejection 
mark, the barrel is unserviceable. 





(a) To check muzzle erosion in an unchromed barrel only, insert muzzle erosion gage (4), PN 8448677, into muz- 

zle. Do not check muzzle erosion on chrome barrels. 

(b) Gage must not go beyond applicable rejection mark or the barrel is unserviceable. 

NOTE 
There are two rejection marks, "A" and "B". Use rejection mark "A" when the barrel 
is being gaged without the flash suppressor assembled. Use rejection mark "B" when 
the barrel is being gaged with the flash suppressor installed. 



3-36 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




GM2, BARREl 

EROSION 

[cmm BORC GUY) 



(a) To check erosion in a chrome barrel only, use barrel 
erosion gage (5) PN 8448496. Install bolt carrier 
assembly with bolt assembly and firing pin removed. 
Insert gage into rear of bolt carrier assembly. The re- 
ject line must be read at the rear edge of the bolt car- 
rier assembly. 

(b) If the reject mark passes below the rear surface of the 
bolt carrier assembly, the barrel is unserviceable and 
must be replaced. 




NOTE 



Ensure barrel is clean prior to performing the 
following test. 



(a) Check straightness of a chromed or unchromed barrel 
using straightness gage (6) PN 8448202. Put gage in 
barrel. Tilt barrel and allow gage to fall through. Catch 
gage. 

(b) Gage must pass freely through barrel. If the gage does' 
not pass through the barrel, recheck as follows: Hold 
the upper receiver and barrel assembly (7) in a vertical 
position with the muzzle pointed down; insert gage in- 
to chamber end of barrel. Release gage and catch it a^ 
it exits the muzzle end. If the gage passes freely 
through the barrel, the barrel is acceptable. If it does 
not, the barrel must be straightened or replaced. (See 
p 3-29 for straighten instructions/procedures). 




3-37 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-13. UPPER RECEIVER AND BARREL ASSEMBLY (CONT). 



e. TEST (CONT} 



Cl>~~^ 



(a) Install charging handle (8), and bolt 
carrier assembly (9) into upper re- 
ceiver (2). 

(b) Insert headspace gage (10) PN 
7799734 in chamber. 




8 



NOTE 



For the purpose of this test "light finger pres- 
sure" is defined as 8 1/2 to 8 3/4 pounds. 

(a) D I e c t h M d s p n E b ^ p in s in g h It u rrie i n s e n b If 
|S) and charging handle (8) forward using light 
finger pressure. 

(b) Bolt carrier assembly (9) must protrude from rear of 
receiver (2) for proper headspace. If bolt carrier as- 
sembly is flush with or indented to rear surface, this 
indicates excessive headspace. 




3-38 



ARMYTM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



9 



nil n I 



(a) If the test fails using finger pressure, remove the 
gage and perform the test again as follows: With 
the muzzle down, stack 8 1/2 to 8 3/4 pounds 
of trigger weights (1 1) on a locally fabricated 
spacer/weight (12) on the bolt carrier assembly 
(9). Insert headspace gage (10) and test per 
above instructions. 

(b) Remove trigger weights (11), spacer/weight (1 2), 
bolt carrier assembly (9), charging handle (8), 
and headspace gage (10). 

(c) If excessive headspace, first replace bolt assem- 
bly and then recheck. if headspace is not cor- 
rected, replace barrel assembly; then recheck 
with the original bolt to determine if the bolt is 
still good or if the bolt should be replaced also. 




NOTE 

Rifles which have been rebarreled must be function-fired with seven rounds 5.56mm 
of ball ammunition. After rebarreling, the rifle must be targeted with three rounds 
5.56mm of ball ammunition at 25 meter range, using target. Refer t o TM 9-10 05-249-101 
and FM 23-9. 



3-39 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

3-14. UPPER RECEIVER ASSEMBLY. 



This task covers: 

a. Disassembly 

b. Inspection/Repair 

c. Clean 



d. Lubrication 

e. Reassembly 

f. Mechanical Zero Procedures (A. F. only) 



INITIAL SETUP 

Applicable Configuration 
All M16/M16A1 rifles except as noted. The M 16 
rifles are not equipped with the forward assist 
assembly. The receivers are different part numbers 
but all other parts are interchangeable. Only the 
M16A1 rifle is depicted. Some rifles may be 
equipped with a low light level rear sight. 

Tools 
Small Arms Repairman Tool Kit 

SC 5180-95-CL-A07 
Field Maintenance Basic Less Power Small Arms 

Shop Set SC 4933-95-CL-A11 (1 9204) 

Materials/Parts 
Cleaner, lubricant and preservative (CLP) (item 9, 
laPP Dt 



Cloth, abrasive (item 12, ft pp DP 
Lubricant, solid film (item 19, ftpp DP 
Lubricating oil, weapons (LAW) (item 20, 

lapp Ul 
Lubricating oil, weapons (LSA) (item 21, 

lapp D^ 

Equipment Condition 

Page Condition Description 
3-23 Upper receiver removed 

General Safety Instructions 

To avoid injury to your eyes, use care when removing 
and installing spring-loaded parts. When using solid 
film lubricant or dichloromethane, be sure the area 
is well ventilated. 



a. DISASSEMBLY 




To noid injny to pyr sfes, yse caie w li e o remMifig aH inUlling spiin^'lnded parls 

c n T 10 fi 

Be sure to n Ic ^ s m a II parls (1 , 1 , 3 , and \] 
a ) D li n Ml spring p I o 1 1 | u s I o 9 a h m m e r and 1 i U ' i n h p u n c L 
b ) C a Ic h real s Ig h t w iH a p drum [l], u a 1 s Ig h t d e lo n t |3 ], and b e Ik a I s p lin g (4 j. 



3 -4 D 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




(a) Using a flat-bladed screwdriver, remove rear sight windage screw (5). 

(b) Remove aperture sight (6), flat spring (7), from upper receiver (8). 

NOTE 

There is no further disassembly for M 16 rifle upper receiver assembly. (M 16 does 
not have forward assist assembly. ) 



NOTE 

This applies to M16A1 Rifles only. 

r i M u \ s p [ i n 9 }\[ | i ) n i n ; i 1 ' M ' i n h d i i n pin 
y n I n d h H h i i e i. 




n t n n foiM id n s is I n n i M| |1 1 1 i H h lin 
s p fi^ 3 111) f[g n j p p n le m in r \l\. 




3-41 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

3-14. UPPER RECEIVER ASSEMBLY (CONT). 



b. inspection/REPAIR 




(a) Visually inspect rear sight parts (1 thru 7) for 
broken, bent, unserviceable condition or missing 
parts. Replace defective or missing parts. 

b) Check helical spring (4) for serviceability, prior to 
disassembly and after reassembly. Replace if 
defective. 

(c) Prior to disassembly and after reassembly, check 
that the flat spring (5) retains aperture sight (6) 
firmly in either position. Replace flat spring (5) if 
sight is not firm. 

d) Check upper receiver (8) for cracks, corrosion, or 
mutilation. Repair or replace upper receiver if 
defective. Refer t d page 3-2$ . inspection/ 
CLEANING. 




(a) To straighten bent rear sight guards (9), remove 
rear sight components. Place carrying handle (10) 
in a vise with top edge of vise at a point just 
below the windage screw hole (1 1 ). Tighten vise 
(11) to firmly hold upper receiver (8). 

(b) Using two eight-inch adjustable wrenches, 
gradually bend guards (9) to straighten. When 
bending the guards (9), gradually bend beyond 
the straight point, as the guard will partially 
return when bending pressure is stopped. 

(c) After straightening, use a flat file to remove any 
nicks, kinks, or burrs that remain on the inside of 
guards (9). 

CAUTION 



Do not use wire brush on aluminum 
surfaces. 

(d) Apply solid film lubricant to brightened area for 
final protective coating. 

(e) Replace rear sight components and check that 
sight functions properly. If sight functions check 
out, return upper receiver to service. 



3-42 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



lal inspect upper receiver for cracks, corrosion, 
mutBiation, wear, or damage. 

f1) Small dents or gouges that do not affect func- 
tioning will not be cause for rejection. 

12) If receiver contains cracks or ho§es, the 

receiver will be replaced. 

^b| Inspect springs for breaks, deformation, and rust, 

ic} Repair corroded ypper receiver surfaces as foHows: 

ni Sand corroded area with abrasive cloth and 
make sure all corrosion has been removed. 

{2} Wash area with technical dichloromethane 
^methylenechloridel to remove all dirt, grease, 
and foreign material. 

131 Apply sealing compound, mixed in accordance 

with manufacturer's directions, to areas to be 

filled. 

|4S Spread sealing compound as smoothly as 

possible into defective area using a putty knife 

or similar tool. 

NOTE 

D@ not feathar @dges. 

^51 Place a sheet of polyethylene, cut to size, over 
filled area. Rub by hand or smooth using small 

roller. 




A - SHINY SURFACES 
(REPARABLE! 




I ' CORRODED 
jREPARABLEI 




C - CORRODED 
INONREPARABLES 



BREAKTHROUGH 
HOLE 




D = BREAKTHROUGH HOLE 
(ACCEPTABLE) 



3-43 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

3-14. UPPER RECEIVER ASSEMBLY (CONT). 
b. INSPECTION/REPAIR (CONT) 



(a) After curing, remove polyethylene sheet in accordance with manufacturer's instructions. 

WARNING 

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

CAUTION 

Solid film lubricant is to be used only as an exterior surface protective finish 
and touch up. If solid film lubricant comes in contact with recoiling parts or 
functional surfaces of the rifle, remove immediately by washing with technical 
dichloromethane. 

(b) Wash area with technical dichloromethane (methylenechloride) to remove all dirt, grease, and foreign 
material. 

(c) Roughen area to be refinished with abrasive cloth and clean surface again. Do not touch the area with 
fingers. 

CAUTION 

Do not use a wire brush on aluminum surfaces. 

(d) Repair shiny surfaces by spraying a coat of solid film lubricant in accordance with manufacturer's Instruc- 
tions. Dry 24 hours before handling 

NOTE 

Solid Film Lubricant (SFL) is the authorized touch up for the M16/M16A1 Rifle and 
may be used on up to one third of the exterior finish of the weapon. 

FOR CONUS USE ONLY: Solid Film Lubricant may be used as a touch up 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% of the exterior surface of the Upper Receiver and Barrel 
Assembly protected with SFL. Prior to application of SFL the surface must be 
thoroughly clean and inspected for corrosion and/or damage. If corroded or 
damaged, the part must be repaired prior to application of SFL, or replaced. 
Continued use under combat conditions would result in an unprotected surface when 
the SFL wears off. This would result in a large light reflecting surface and accelerated 
deterioration of the unprotected surface. Therefore, Divisional Combat Units and 
units which fall under the definition of Rapid Deployment type must adhere to the 
limitation of NOT over 1/3 of their exterior surface covered by SFL 

(e) Inspect all parts for damage and wear. Replace all defective parts. 



C. CLEAN 



Clean rear sight and forward assist portions of upper receiver and all components. 



d. LUBRICATION 



Lubricate upper receiver assembly. Apply CLP, LSA, or LAW (see p 2-22) to helical springs, threaded portion of 
screws, forward assist and sight before installation. 



3-44 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COASTGUARD COMDTINST M8370.9 



€. REASSEMBLY 





NOTE 
M16A1 rifles only. 

(a) Apply CLP LSA, or LAW (see p 2-22) to helical spring (1) and forward assist assembly (2) and install them 
into upper receiver assembly (3). 

(b) Install spring pin (4) using 3/32-inch drive pin punch and hand hammer. 



2 (ih—^ 





NOTE 
All M16 rifles. 

(a) Apply CLP, LSA or LAW (see p2-22) to flat spring (5), aperture sight (6), and threaded portion of rear sight 

windage screw (7). 

[b I in \i II 111 t s f rin f |S | a H aperature sight (6) with letter "L" to rear. 

(c) Install rear sight windage screw (7) using flat tip screwdriver. Tighten screw. 

L_^ ^ __- 



3-45 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

3-14. UPPER RECEIVER ASSEMBLY (CONT). 



e. REASSEMBLY (CONT) 




H A 



I n nd in jn) U ) m i e ) t s . y n u re « h m it i n in g n d in ta lli^ g s p lin g -io H t d pits 

(a) In h II h Ik i i spiin; {l\. ini sigh detnl (9|, nd iin s ig H wiHage dnn IH]' 

(b) S t M I e b r i n h I i i n ; s p i i n ; pin (1 I | y s i p 1 il ( ' I n I d r I m pin p n c h n d h n d h n i e i . 



f. MECHANICAL ZERO PROCEDURES 



1 



C n tn fu f s ig H b I n m in 9 lu f s 
i p p 10 p lis te d iiM tio n . 



t d ry I \] \\ n 




3-46 



Always push in on bolthead after making rear sight 
adjustments. 




1 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



fin 3 llf c h E I h in r sight Id e n ne il is c m te re d a fie i 
I 1 Hn g H jn tn e n Is . Also, e n n: II ! in i s ig H is 
s e I i^ th s h it-ii n p |u n n a il e d i p e itu le | pes itio [ . 




IE ; P IE 
e 10 tE 10 
1 p Ie tE d , 
i ( I ! le IS 
u IE n d i 

p E itHE . I 

iiin g i n 
E d H! h 



E d H! till g in n a p p ro i in a tE h MIe s ile 

t M H rilie s . I) n le the a h n s le p s are 
Ih e lilie K iii be n e c I a a ic a 11^ z e ro e d It i 
a s il g Ih e y n I a riE d e i s h o it-ia n p a p e r- 
Mi I E t E r s using lie ' L " e i i o a g - 1 a n g e 
E a h ( E s tE p s tan a is a b e u s e d b e fa le 

1 a E I if 1 s s ig n E d lilie , Use th e p n - 
h E c I liflE s s la re d ia p le le tie d p n h g ia g 
nin g id y tin a in p e e tio n . I I is till h e ip e a s a le p e o - 
le a II E d * ilh Ih e lilie s i iii s ta a d i b e tte i e h a { e 
I I illia g an e a e in ^ il Ile lilie s i y s t be y s e d b e lo ie 

lin liie z E la a a a b e la a d e . H I e a e i e i p a s s ib ie ^ 
e 10 in g a I tl e lifla s h o a Id be a t n ai p iis I e d y s in g b a i 
il la u n ilia a a a a M la e le i z e ra ia g la ig e t y s ia g lb e 
L ' a a a itu IE . 



3-15. FORWARD ASSIST ASSEMBLY. 



T h is U s I a a V e IS : 

a . D is a s s E I b If 
b . la s p e a lia a 
c . Me a a 



d , I a b ric a ta 

i . II ! p a il 

I, II e a s s e 1 b If 



iMi in SE n p 

1 p p lia a b iE C a a fig a la tia a 
Mini rilie a a if 

I a Is 

S I HI Ills I E p nil a a I a a i lit 

n s I n -n -n -n I |i s n 1 1 

F ia id U a ia tE a a a n E a s ia less P a i e r S i a ii 1 iia s 
Hap Sal H H H 'S ! 'CI -M I (M M 1 

II a t e I i a I s J P ails 

C Jt a a 1 1 | I la b rii a a t aad presErntin (DIP) (ilein 9 

ill T 



I a b lie a tin g a il, weapons (U I | (ile la U . i p p y i 
I y b iIe a tia g a ii, i e a p a a s |L SI | (ile ii M , i a a y i 

E q u ip la a n t C a a d itio a 

P a p E C a n d il ia a D e s c i ip tio n 

I -U F E rw a I d assist a s s a la b If i e i e i e d 

G e a E la i S a Ie tf la s tiu a lio a s 

la a n id ia |a if to f a a r e f a s , use a a le h h a n re la a nn g 

aad ia s ta iiia a s a fia a -io a d e d a a lis . 



MI 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

3-15. FORWARD ASSIST ASSEMBLY (CONT). 



a. DISASSEMBLY 




WARNING 
To avoid injury to your eyes, use care when removing and installing spring-loaded parts. 
1. Drive out spring pin (1 ) using 1/16-inch drive pin punch and hammer. 
2. Remove forward assist pawl (2), pawl detent (3), helical spring (4), from plunger assembly (5). 



b. INSPECTION 



1. Inspect forward assist pawl (1 ) for deformities, burrs, 
chips, and cracks. Minor burrs may be removed using fine 
files or stones, as required. Replace pawl if defective. 

2. Inspect pawl detent (2) for deformities. Replace detent if 
defective. 

3. Inspect helical spring (3) for kinks, breaks, and wear. 
Replace spring if defective. 

4. Inspect plunger assembly (4) for wear, burrs, chips, and 
breaks. Minor burrs may be removed using fine files or 
stones, as required. Replace if plunger assembly is 
defective. 

5. Inspect spring pin (5) for wear or deformities. Replace if 
defective. 




c. CLEAN 



Clean all parts of the forward assist assembly. 



3-48 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



d. LUBRICATE 



Lubricate helical spring, pawl detent, and forward assist pawl with CLP, LSA, or LAW (see p 2-22) before 
installation. 



e. REPAIR 



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

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

3. Replace unrepairable parts. 



f. REASSEMBLY 





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

1. Install helical spring (1), pawl detent (2), and forward assist pawl (3) into plunger assembly (4). 

2. Align holes and install spring pin (5) using 1/16-inch drive pin punch and hammer. 



3-49 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-16. LOWER RECEIVER AND EXTENSION ASSEMBLY. 



This task covers: 






a. Disassembly 




e. Clean 


b. Inspection 




f. Lubricate 


c. Repair 




g. Reassembly 


d. Test 






INITIAL SETUP 
Applicable Configuration 






Cleaning compound, rifle bore (RBC) (item 11, ^pp Db 


All M 16/M16A1 rifles. All parts are the same except 


Dichloromethane, technical (item 14, ^pp \)} 


for lower receiver body which is different 
that it specifies the different models and 


only in 
the serial 


Lubricant, solid film (item 19. Add DI 


Lubricating oil. weapons (LAW) (item 20. fapp Db 


numbers. 




Lubricating oil, weapons (LSA) (item 21. bPP DI 
Screw, self-locking (butt-cap screw) (item 28, p C-10) 


Test Equipment 






Tool and Gage Set 8426685 (1 9204) 




Equipment Condition 

Page Condition Description 


Tools 




3-10 Lower receiver and extension assembly. 


Small Arms Repairman Tool Kit 






SC 5180-95-CL-A07 (19204) 




General Safety Instructions 


Field Maintenance Basic Less Power Small 


Arms 


To avoid injury to your eyes, use care when removing 


Shop Set SC 4933-95-CL-A11 (19204) 




and installing spring-loaded parts. 


Pivot pin removing tool (locally fabricated 


tool) 


When using solid film lubricant or dichloromethane, be 


Kfiq E-2j NPP El 




sure the area is well ventilated. 


Materials/Parts 






Cleaner, lubricant and preservative (CLP) (item 9, 




1 app D» 







a. DISASSEMBLY 



1 




©X^ 




WARNING 

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



(a) Remove spring pin (1) using 3/32-inch drive pin punch and hammer. 

(b) Remove bolt catch (2), bolt catch plunger (3), and bolt catch spring (4). 



3-50 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




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

(a) Using drive pin puncli, press in on magazine button (5) and turn magazine catcli (6) counterclockwise to 
unscrew and remove. 

(b) Remove magazine button (5) and magazine catch spring (7) 




(aj Use a drive pin punch to push automatic sear pin (8) out of lower receiver (9). 

NOTE 
To remove sear, safety selector lever must be positioned to automatic (if installed). 

(b) Remove automatic sear (10) and safety selector lever (11 ). 



3-51 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



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



a. DISASSEMBLY (CONT) 





W A RN ING 
To avoid injury to your eyes, use care when removing and installing s p rin g -lo a d e d parts. 

NO TE 
To remove (hammer should be forward), place safety selector lever (if installed) to SEMI position 

a) Use drive pin punch to push hammer pin (12) from lower receiver (9), 

b) R e m V e hammer assembly (13). 




(a) Remove trigger pin (14) by pushing from the left side of lower receiver (9) with a drive pin punch. 

(b) Remove disconnector (15) and trigger assembly (16) from lower receiver and extension subassembly (1 7). 



3-52 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



b. INSPECTION 



1 





^WWl 



A ■ SHINY SURFACES 

- (REPARABLE) a - SHINY SURFACES 

- (REPARABLE) 



B = CORRODED AND NO HOLES 
- (REPARABLE) 



B - CORRODED 

- (REPARABLE) 





C - CORRODED LOBES - WEAKENING 

PIVOT PIN AREA 

- (NONREPARABLE) 



C = CORRODED WITH HOLE 
= (NONREPARABLE) 

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 
Apply solid film lubricant to shiny surfaces. 

Solid Film Lubricant (SFL) is the authorized touch upforthe M16/M16A1 Rifle and may 
be used on up to one third of the exterior finish of the weapon. 

FOR CONUS USE ONLY: Solid Film Lubricant may be used as a touch up without limita- 
tion 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% of the exterior surface of the Upper Receiver and Barrel Assembly 



3-53 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



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



b. INSPECTION (CONT: 



I (CONT) 

NOTE (CONT) 

protected with SFL. Prior to application of SFL the surface must be thoroughly clean and 
inspected for corrosion and/or damage. If corroded or damaged, the part must be repaired 
or replaced prior to application of SFL. Continued use under combat conditions would 
result in an unprotected surface when the SFL wears off. This would result in a large 
light reflecting surface and accelerated deterioration of the unprotected surface. Therefore, 
Divisional Combat Units and units which fall under the definition of Rapid Deployment 
type must adhere to the limitation of NOT over 1/3 of their exterior surface covered by SFL. 

If a M16/M16A1 Rifle LOWER RECEIVER is missing one third or more of its exterior pro- 
tective 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. 

Once the missing exterior protective finish of the lower receiver has exceeded one third 
of its total surface the probability of reclaiming the receiver during overhaul diminishes 
rapidly. In order to extend the life of the lower receiver, which is the serial numbered 
item, it is necessary to evacuate the weapon to depot once the missing finish reaches 
one third of the total surface of the receiver. 

(a) Inspect lower receiver and extension subassembly (1 ) for corrosion in the lower receiver lobes of the pivot area 
or hinge pin area. 

(b) If extensive corrosion appears in these areas the receiver will not be repaired and rifle will be turned in for 
replacement. 

(c) Inspect selector lever stops. If either is missing or damaged/worn to the point of being nonfunctional, the rifle 
will be turned in for replacement. 

NOTE 



Refer to l page 3-531 INSPECTION/CLEANING for repair procedures for corroded surfaces 



3-54 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



i 



y 



A-SHINY SURFACES 
(REPARABLE) 




THIN WALLS 






HOLES 



(t 



L 



B-CORRODED 
(REPARABLE) 




^CT 



C-HOLES AND THIN WALLS 
(NONREPARABLE) 




\r^ 



Inspect extension (2) portion of lower receiver and extension subassembly for corrosion. Repair or replace if 
defective. 

NOTE 



Refer to lpaqe 3-53.I INSPECTION/C LEANING for repair procedures for corroded surfaces. 







\\ In nn h n d e fo rn ill! s , In p e c t Ifigg > ' '° ^ i n i, na c h d f d Hni itin . H p N c e \ 



c. REPAIR 



tpiii n itpliie all pnM \\ \\\ w innni \\i nlnsln nniiMf if dHntIn 



! -n 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



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



d. TEST 




LOWER 
RECEIVER 



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

(a) Apply hand pressure to push the upper receiver as far to one side as possible 

(b) Attempt to insert a .020" thickness gage between the pivot pin lugs of the upper and lower receivers 

(c) If the thickness gage penetrates to the pivot pin at all accessible locations, repair by replacement of the up- 
per receiver (see para 2 below) or replacement of weapon is required. 

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

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

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

NOTE 

Failure of any portion of this test is considered a shortcoming until such time as a replace- 
ment weapon or repair parts are received. 



3-56 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




SIDE 
VIEW 



NOTE 



NOT-GO GAGE 12006472 



ff the lower receiver is not disassembled, visuaffy Inspect for broken or cfamaged* parts, 
and insure that the hammer and trigger springs are correctly installed before beginning 
this test. It is not necessary to disassemble the lower receiver for the sole purpose of 
this visual inspection. If broken or damaged parts are found, disassemble (p 3-50) and 
repair as authorized. 

5. Test two hammer pin holes and two trigger pin holes using not-go plug gage (1) P/N 12006472. This test may 

be conducted by disassembly of the lower receiver (p 3-50) or by pushing the pin far enough to disengage the 
end of the pin from the side of the receiver which is being tested. If the lower receiver is not disassembled and 
the not-go plug gage enters any hole to first shoulder (A) the lower receiver must be disassembled and all four 
holes must be tested again. 

6. Gently insert the not-go plug gage and rotate it 180 degrees. If the no-go plug gage passes through any of the 
four pin holes, the rifle is unserviceable and will be turned in for replacement. The gage must penetrate through 
the wall thickness to be unserviceable. 



e. CLEAN 



WARNING 
When using technical dichloromethane, be sure the area is well ventilated. 
Clean lower receiver and extension assembly with technical dichloromethane. 



f. LUBRICATE 



WARNING 
When using solid film lubricant be sure the area is well ventilated. 
Lubricate all items with CLP, LSA, or LAW (p 2-22) before reassembly. 



3-57 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



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



g. REASSEMBLY 



1 




R^. «. a« 



(i^ilF|^^ 



(a) Install trigger assembly (1) and disconnector (2) into lower receiver and extension subassembly (3). 

(b) Install trigger pin (4) using drive pin punch. Push in until flush. 




NOTE 

E H s f h n n M s p lin g 3 le in ta He d h in i o f tiigg si p in |l |, in lin g in lie n n h i g lo d n 
n upper n ifn e of tiig p ' M^ IH' 

In s t3 li h 3 n I e I i n e i b if (S |. 

\ ] in ti ii h 3 in in M pin [i] y s in g drive pin p y n c L P y s I in n lii fli s L 



3-58 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




NOTE 

Selector lever (7), if installed, must be positioned in automatic. Long leg of automatic 
sear (8) spring must rest on top of selector lever. 

(a) Install selector lever (7) and automatic sear (8). 

(b) install automatic sear pin (9) into receiver using drive pin punch. Push in until flush. 



NOTE 

Be sure the magazine button is Installed 
correctly, with the grooved face on 
the outside of the rifle. 




10 In h II li 3 g M In e u U I s p ih g |l I j u i i i p z In e b Htn (11). 

|b) In h II nsgnln calch |M)' ^^^^ i^ in iisH^'"^ htin \\ 1 | nhg i d lin pin puni nd 
(M I t lo t U is e y Mil Ihn d H end o I c i tt h Is I In I k ilh i i g h in h lU n I m d . 



|y in I M n In c i It h 



S 'H 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



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



g. REASSEMBLY (CONT) 








(a) Install bolt catch spring (1 3), bolt catch plunger (14), and bolt catch (15). 

(b) Secure by installing spring pin (16) using 3/32-inch drive pin punch and hand hammer. 



3-17. HAMMER ASSEMBLY 



This task covers: 




a. Inspection 


c. Reassembly 


b. Repair 




INITIAL SETUP 




Applicable Configuration 


Equipment Condition 


All M16/M16A1 Rifles 


Page Condition Description 




3-50 Hammer assembly removed 



a. DISASSEMBLY 



Remove hammer spring (1) from hammer (2). 



j c 


f 


y 




3-60 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



E 



b. inspection/REPAIR 



1. Inspect hammer spring for deformities, breai^s, and bends. Replace if defective. 

2. Inspect hammer for chips and breaks and excessive wear on automatic sear notch, disconnector notch, or sear 
notch. Replace if defective. 

3. Install hammer pin into hole in hammer to check if the spring retains the hammer pin. 



c. REASSEMBLY 



Install hammer spnng (1) on hammer (2). 




3-18. TRIGGER ASSEMBLY. 



This task covers: 

a. Disassembly 

b. Inspection/Repair 



c. Reassembly 



INITIAL SETUP 

Applicable Configuration 
All M16/M16A1 Rifles 

Equipment Condition 

Page Condition Description 
3-50 Trigger assembly removed 



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



I a- DISASSEMBLY 



Remove disconnector spring (1) and 
trigger spring (2) from trigger (3) 



I*-© 




3-61 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3-18. TRIGGER ASSEMBLY (CONT). 



b. INSPECTION/REPAIR 



1. 


Inspect 


trigger 


spring 


for kinks, 


deformities, 


and weakness. 


Replace 


if defective. 




2. 


Inspect 


disconnector 


spring 


for 


deformities. 


bends. 


breaks. 


and weakness. Replace 


If defective. 


3. 


Inspect 


trigger 


for ch 


ps and 


cracks and excessive 


wear on 


trigger 


nose. Replace if 


defective. 



c. REASSEMBLY 



1. Install disconnector spring (1 ) by inserting 
large end of spring into trigger (2). 

2. Install trigger spring (3) on trigger (2). 



h-<D 




3-19. LOWER RECEIVER AND EXTENSION SUBASSEMBLY, 



This task covers: 




a. Disassembly 


d. Test 


b. Inspection 


e. Reassembly 


c. Repair/Modify 




INITIAL SETUP 




Applicable Configuration 

All M16/M16A1 rifles. The lower receivers have 
serial numbers and model numbers and will 


Materials/Parts 


Cloth, abrasive (item 12. ioo D\ 


Urease, molybdenum disulfide (item 17, fapp D\ 


not be replaced by Direct Support 


Lubricant, solid film (item 19. ipp Dl 


Maintenance. 






Equipment Condition 


Test Equipment 


Page Condition Description 


Tool and Gage Set 8426685 (1 9204) 


3-50 Lower receiver and extension subassembly 




removed. 


Tools 




Field Maintenance Basic Less Power Small Arms 


General Safety Instructions 


Shop Set SC 4933-95-CL-A11 (19204) 


To avoid injury to your eyes, use care when removing 


Small Arms Repairman Tool Kit 


and installing spring-loaded parts. 


SC 5180-95-CL-A07 (19204) 





3-62 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



a. DISASSEMBLY 




(a) Remove spring pin ('i ) from lower receiver and extension subassembly (2) using l/S-mch drfve pm punch and 
hammer. 

(b) Remove trigger guard (3). 



NOTE 

Old type receiver extension requires removal 
discard of spring pin (4). 

(a) II s p fi^ 3 p li 10 is in ta IIH , fe li M e n d Hs u id 

|b ) II d iff It f i I re M in I n Im s in p fin U 

inn fi Hj, S i li }Ui \M , B [ M iM MF ( , 




3-63 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-19. LOWER RECEIVER AND EXTENSION SUBASSEMBLY (CONT). 




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

NOTE 

Grip the solid portion of the lower receiver with wooden or brass vise jaws. Use wooden 
vise jaws instead of brass vise jaw caps if available. 

(a) Clamp lower receiver and extension subassembly (2) in a machinist's vise using vise jaw caps and tighten on 
solid portion just tight enough to hold, 

NOTE 

As lower receiver extension is removed, catch buffer retainer and spring. Lower receiver 
is a serial number controlled item. 

(b) Remove lower receiver extension (5) from lower receiver (6) using combination wrench and socket wrench han- 
dle. Catch buffer retainer (7) and helical spring (8). 



b. INSPECTION 



1. Inspect lower receiver extension (1 ) for corrosion, 
dents, and wear. Repair or replace if defective. See 

Ipaqe 3-5g , REPAIR. 

2. Inspect buffer retainer (2) for wear and replace if 
defective. 

3. Inspect helical spring (3) for deformities and 
breaks. Replace if defective, 

4. Inspect lower receiver (4) for corrosion, wear, and 
damage, Se b page 3^ 3. INSPECTION. 

5. Inspect trigger guard (5) for deformities and check 
operation of plunger and spring (6). Replace trigger 
guard if defective. 




3-64 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



c. REPAIR/MODIFY 



Repair lower receiver extension (1) by using abrasive 
cloth to remove light corrosion. Retouch using solid 
film lubricant, 




OLD 



MODIFIED 



MODIFIED 




NOTE 
Lower receiver extensions are usable after forming of flats. 

d iff lo w ( [ lecMur MtHsins (1 | |h I n reqnrHj U ahn d m in 9 d in n s it n ysin; file hHlt. hiH fife 
c llns t's V In . n d vise \u caps. 



jal In s p e 1 1 h « n fe n in 1 {l\ ft 1 d a m i g e . m i i 

a Hi M riM in {} I -W], Repair n n p ii c e 
H e a p M . 

CAUTION 



Use extreme care when drilling hole so that 
you do not penetrate inner wall of spring 
Cavity . 

NOTE 




1/16 INCH 

(.062 DIA) 
HOLE DRILLED 
INTO SPRING 
CAVITY 



Spring must be removed before drilling. 

(b) Modify lower receiver (2), when required, to 
dimensions depicted using 1/1 6 twist drill and 
portable electric drill. 



3-65 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-19. LOWER RECEIVER AND EXTENSION SUBASSEMBLY (CONT). 



If serial number is hard to read on weapon, restamp as follows" 

(a) Support the receiver in the stamping area to prevent bending and distortion of the receiver. 

(b) Exercise extreme care to restamp the same serial number as original 

(c) Restamp the serial number the same size as the originalserial number. 

NOTE 



Most weapon serial numbers are 1/8 inch in height, or close enough that this size 
is acceptable for such restamping. In the event that a weapon has a serial number 
that cannot be reproduced by the use of the die sets, local purchase of an appropriate 
size die set is authorized. 

Replace defective components as authorized 




d. TEST 



Test lower receiver and extension subassembly trigger pin holes and hammer pin holes, 
lower receiver lobe area spacinq. Sele paqe 3-5B, TEST. 




Test 


Seel paqe 3-56.| 



3-66 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



e. REASSEMBLY 



e— ® 



I n I li fl 

I 1 n id i^ jy [f to p y i e | m . m n n ( h u n i m in g 
1 H ins ti iiin I s p ri^ g 'In d H p i lis . 

n N ii h ! lie i i s p rh g |l | n d b y It! i i! Ii in i {1\ into h i n it c mm i (1 




(a) I y b fiu te thuds H io i t r it c ein r (3 1 n d inn 
iM MH [ n tn s it ^ |4 I Mil I l| b d n u I din itid e 
g iM s e b e U re in s h Di b if . 

(b) In li ii it ( e I rM ein I n Is n in |t | iHo in m i 
in i in [ {l\ i Hie d e p in s i^ g b n tin le ti in e i [l]. 





Ij H « n d M lin jn s in n n c I inis t'a vin in pine o I bins vis t \n n p s . it n i iii b it . 

C in in p s Hid p o itie n el le m i le e e in i end n In s in n s e di b l| |! | in a n a e I in is I's v is e u s i^ g t o H e n lis e jn s 

Using t D in b in e tie n i i n i I t t D t H H |S | n d Inq u e u le n e I . to i q y e io » e i le t e in i e i te n io n U S HH tl-ib . 

I iq n e is lead i b ( n both mo n e I e s lie n e d Id g e tl e i. 



3 ■! I 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3-19. LOWER RECEIVER AND EXTENSION SUBASSEMBLY (CONT). 




(a) Install trigger guard (7) into lower receiver and extension assembly (5). 

(b) Fasten with spring pin (8) using 1/8-inch drive pin punch and hammer. 



3-20. MAJOR COMPONENTS OF M16 AND M16A1 RIFLE. 



This task covers: 




a. Reassembly 


b. Test 


INITIAL SETUP 




Applicable Configuration 
All M16/M16A1 Rifles 


Reference 


|TM 9-1005-249-10 floperator's manual) 


Test Equipment 


Equipment Condition 


Tool and Gage Set 846685 (1 9204 


Weapon disassembled 


Tools 


General Safety Instructions 


Small Arms Repairman Tool Kit 


To avoid injury to your eyes, use care when removing 


SC 5180-95-CL-A07 (19204) 


and installing spring-loaded parts. 




Live ammunition must not be near the work area. 



3-68 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



a> REASSEMBLY 




M16A1 



1. Refer to operator's manual. 

2. Install charging handle (1) and bolt carrier assembly (2) into upper receiver assembly (3). Join upper receiver 
assembly (3) and lower receiver assembly (4). 

3. Snap on small arms sling (5) and install cartridge magazine (6). 



I b, TEST 



1. Place test fixture rod (1) on bench and add test weights (2) until minimum load of 5.5 lbs is reached. 

2. Charge the rifle. Place the selector lever in the semi position. 

3. Hold the rifle (3) in a vertical position. Place the end of 
the test fixture (1) over the trigger (4). Slowly raise the 
rifle in a line parallel to the barrel until the fixture and 
weights are suspended. 

4. The hammer must not fall. If the hammer falls, the trig- 
ger pull is too light and the trigger and/or hammer must 
be replaced. Replace the trigger and/or hammer in accor- 
riannp with the maintenance procedures provided on 

* p ag e s 3 - 6(l and 3-61. If replacement of hammer and/or 
trigger fails to correct light trigger pull, replace hammer 
springi ( pg 3 -60 and 3-61). 

5. Add weights until maximum load of 8.5 lbs is reached. 
Repeat the above procedures. The hammer must fall. If 
the ham mer does not fall, replace the trigger and/or ham- 
mer {se e pg - and 3-61). 

NOTE 



(2 LB, 8 OZ) 



Hammer must not trip until 5.5 pounds have been 
applied, and it must trip on applying 8.5 pounds. 




(jy^ 



(1 LB, 8 OZ) 



(2 LB, 8 



3-69 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3-21. Ml 6 AND M16A1 RIFLE FINAL INSPECTION. 



This task covers: 




a. Inspection 


b. Test 


INITIAL SETUP 




Applicable Configuration 
All M16/M16A1 Rifles 


General Safety Instructions 

Live ammunition must not be near the work area. 


Test Equipment 

Tool and Gage Set 8426685 (1 9204 




Tools 




Small Arms Repairman Tool Kit 
SC 5180-95-CL-A07 (19204) 




Reference 


Before starting an inspection on a weapon equipped 
with a low light level sight, check for damage to the 
low liaht level siaht. See procedures listed onl oaael 
2-19. 


TM 9-1005-249-10 floperator's manual) 


Equipment Condition 
Weapon assembled 



a. INSPECTION 



1 



(a) Visually inspect general appearance of weapon. Weapon should look almost new. All metal surfaces are to 
have a dull, rust-or corrosion-resistant finish with no burrs or deep scratches. Solid film lubricant (item 19.1 appi 

[Q is the only authorized touch up for this weapon. 

(b) Visually inspect barrel for serviceability. Barrels must be straight, clean, free of rust, powder fouling, and free 
of bulges and rings. Fine pitting is allowable. 

(c) Visually inspect weapon for missing parts and serial numbers. All parts must be attached and all modifications 
must be applied. Serial numbers must be legible and steel parts must be rust free. Spring pins must be secure 
and screws must be tight. 



i ] I. 



! U r U 1 p naln's m n y i I n d use Ih e 



FuKlionllf in s p e c I h^ nd h II niiiei n ss n b 1^ nd gn tu b ! Hig 
lo lU » in 3 p in H y IM : 

(a) Disengage the takedown pin and open the receiver. 

(b) Remove bolt carrier assembly. 

(c) Remove bolt assembly from bolt carrier assembly. 

(d) Insert bolt carrier and key into upper receiver and barrel assembly. The bolt assembly must not be installed 
while performing test. 

(e) Slide bolt carrier and key forward to detect binding between key and bolt carrier assembly and gas tube by 
feel. Badly bent gas tube could cause damage to both the key and bolt carrier assembly and the gas tube. A 
slightly bent gas tube will cause unnecessary wear of the carrier and key assembly and gas tube. 

(f) Correct slight binding by removing hand guards and slightly bending gas tube in the handguard area while 
repeating step (e) above until no binding is detected. Badly bent gas tubes will be replaced and realigned. 

(g) Remove key and bolt carrier assembly from upper receiver and barrel assembly. 
(h) Reassemble bolt assembly into key and bolt carrier assembly. 

(i) Reinstall bolt carrier assembly into upper receiver and barrel assembly. 



3-70 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-21. M16 AND M16A1 RIFLE FINAL INSPECTION (CONT; 



a. INSPECTION (CONT) 



(a) Make the following functional checks on assembled rifte with selector lever in SAFE, SEMI, and AUTO 
2 position. The test sequence is used for a rapid complete check. Any portion may be used alone to deter- 

mine the operational condition of any special firing' position selected: 

(1) Remove magazine, if installed. 

(2) Pull charging handle assembly to rear. Check that chamber is clear. Let bolt and bolt carrier close. Leave 
hammer in cocked position. Do not pull trigger. 

WARNING 



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

(3) Place selector lever in SAFE position and pull trigger. Hammer should not fall. 

(4) Place selector lever in SEMI position. 

(5) Pull trigger. Hammer should fall. 

NOTE 

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

(6) Hold trigger to the rear, charge weapon and release the trigger with a slow, smooth motion without hesita- 
tions or stops, until the trigger is fully forward (an audible click should be heard). Hammer should not fall. 

(7) Repeat the above selector lever 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, see repair of lower receiver 
and extension assembly (p 3-55). 

(8) Place selector lever in AUTO position. Charge weapon and pull trigger. Hammer should fall. 

(9) Hold trigger to the rear, charge weapon, and release trigger. Pull trigger. Hammer should not fall. Automatic 
assembly sear should have released the hammer as the bolt closed. 

(10) With the hammer in the forward position and using finger/thumb pressure, attempt to place the selector 

lever in SAFE position. The selector lever must not move into SAFE position. 

(b) Perform the following additional functional checks and adjustment on assembled rifle: 
( 1 ) Press magazine catch button. Make sure it functions properly. 

(2) Press bolt catch. Make certain it operates smoothly and holds bolt in open position. 

(3) Adjust front sight and rear sight. Make certain they can be adjusted properly. Refer to operator's manual. 

(4) Actuate forward assist assembly (M16A1 rifles only). It must work freely. 



b. TEST 



1. Check headspace using headspace gage PN 7799734. S de page 3-3I B. TEST. 

2. Check firing pin protrusion using firing pin protrusion gage PN 7799735. Se b page 3-1B . TEST. 

3. Check extent of barrel erosion using barrel erosion gage PN 8448496 or PN 7799792. See Ipaaes 3-351 and 
3-37, TEST. 

Check muzzle erosion using muzzle erosion gage PN 8448677 (non-chrome barrels only) (p 3-35). 
Check barrel straightness using barrel straightness gage PN 8448202 (p3-37). 
Check firing pin hole using firing pin hole gage PN 12620101 (p 3-1 8). 
Refer to trigger pull test (p 3-69). 



3-71 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



3-22. M16 AND M16A1 RIFLE ANNUAL INSPECTION AND GAGE REQUIREMENTS. 



This task covers: 
a. Inspection 



b. Gaging 



INITIAL SETUP 

Applicable Configuration 
All M16/M16A1 Rifles 

Test Equipment 
Tool and Gage Set 8426685 

Tools 

DA Form 2407 

Small Arms Repair Tool Kit 

SC 5180-95-CL-A07 (19204) 
Field Maintenance Basic Less Power Small Arms 

Shop Equipment SC 4933-95-CL-A11 (19204) 

Reference 
ITM 9-1005-249-10 (operator's manual) 
AFR 50-36. Volume 1 

Equipment Condition 
Weapon assembled. 

General Safety Instructions 
To avoid injury to your eyes, use care when 

removing and installing spring-loaded parts. 
Before starting an inspection on a weapon 
equipped with a low light level sight, check for 
damage to the sight and decontaminate if re- 
quired. See procedures i p L;napier~p , Section V. 



All rifles used at training centers (Army only) should 
be inspected and gaged at the end of each training 
cycle. This gaging/inspection will be conducted at 
the discretion of the unit commander. However, the 
time between inspection shall not exceed one year. 

All Active Army M16/M16A1 rifles must be inspected 
and gaged at least once annually for safety. 

All Army Reserve and Army National Guard 

M16/M16A1 rifles must be inspected and gaged at 
least once every two years, after the initial inspec- 
tion/gaging procedures have been accomplished. 
This two year interval may be maintained unless 
preventive maintenance checks and services 
(PMCS), or other physical evidence indicates that 
an individual unit's M16/M16A1 rifles require in- 
spection at a more frequent interval. If it is deter- 
mined 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. 

Air Force Ml 6 rifle will be inspected in accordance 
with AFR 50-36, Volume 1, Chapter 5. 



a. INSPECTION 



Visually inspect general appearance of rifle. Overall appearance will be approximately that of a new weapon. For 
inspection criteria refer to final inspection. I page 3-73J All visual and functional inspection requirements must be 
met. 

NOTE 

To perform the following tests, disassemble weapon only as far as allowed in 
I Chapter ~T] (Unit Maintenance Instructions), unless a deficiency is uncovered. 



2. Perform a general inspection of rifle pe l* chapter 3 (Direct Support Maintenance Instructions) section V. Repair 
as required and authorized. 



3-72 



ARMY TM 9-1005-249-238LP 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



3-22. M16 AND M16A1 RIFLE ANNUAL INSPECTION AND GAGE REQUIREMENTS (CONT). 



b. GAGING 



1. Gage bolt assembly for firing pin protrusion using firing pin protrusion gage FN 7799735. S de page 3-1B . TEST. 

2. Gage bolt assembly for firing pin hole wear using not-go plug gage FN 12620101. S de page 3-1B . TEST. 

3. Inspect chamber in upper receiver and barrel assembly using chamber reflector tool FN 8448201. See I page! 
I3-26J inspection/CLEANING. 

4. Gage barrel in upper receiver and barrel assembly using barrel erosion gage FN 7799792 or FN 8448496 as ap- 

plicable. Use muzzle erosion gage FN 8448677 on nonchromed barrels only. Use bore straightness gage FN 
8448202 on all barrels. See l pages 3-3B through 3-39, TEST. 

5. Check headspace in upper receiver and barrel assembly by inserting headspace gage FN 7799734 in chamber. 
See l page 3-39 , TEST. 

6. Gage hammer and trigger pin holes in lower receiver assembly using not-go plug gage FN 12006472. See l page) 
[3:56] TEST. 

7. Gage trigger pull using trigger pull measuring fixture FN 7274758. Se fe page 3-69 . TEST. 

8. Document inspection with DA Form 2407 and DD Form 314 when completed. Air Force users refer to AFTO 

Form 105. 



Section VI. FREEMBARKATION INSPECTION OF MATERIEL IN UNITS ALERTED FOR OVERSEAS MOVEMENT 



3-23. GENERAL. Refer to TB 9-1000-247-34. 



3-73 (3-74 blank) 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

CHAPTER 4 
MAINTENANCE OF AUXILIARY EQUIPMENT 
CHAPTER OVERVIEW 
This chapter contains information and instructions to keep auxiliary equipment used with your weapon in good repair. 

Section I. UNIT AUXILIARY EQUIPMENT 
4-1. GENERAL. This chapter covers Unit and Direct Support Maintenance of Auxiliary Equipment. 

a. The following materiel is used in conjunction with the M16/M16A1 rifle: 

(1) Bayonet-knife M7, NSN 1005-00-073-9238. 

(2) Bayonet-knife scabbard M10, NSN 1095-00-223-7164. 

(3) 40-mm Grenade Launcher M203, NSN 1010-00-179-6447. 

(4) Low Light Level Sight (front), NSN 1005-00-234-1568, Low Light Level Sight (rear), NSN 1005-00-071-8015. 

NOTE 

The Low Light Level Sights (front and rear) are no longer being manufactured and 
are obsolete items. 

(5) Lock Plate, NSN 1005-00-233-9031. 

(6) Top Sling Adapter, NSN 1005-00-406-1570 

(7) Rifle Bipod M3, NSN 1005-00-992-6676. 

(8) Bipod Carrying Case, NSN 1005-00-283-9439. 

(9) Blank Firing Attachment M15A2, NSN 1005-00-118-6192. 

b. Refer to TM 9-1 01 0-221 -24&P for unit maintenance for the Grenade Launcher M203. 



I 



c. Refer to TM 9 -1005-237-23&P fo r repair instructions and repair parts for Bayonet-Knife M7 and Bayonet-Knife 
Scabbard M10. 

d. Refer to TM 9-6920-363-1 2&P for unit maintenance of the M261 Conversion Kit (caliber .22 rimfire adapter). 

e. Coast Guard (ONLY) NAVSEA OP 4445 M87 MOD 1 Line Throwing Rifle Adapter Kit. 



4-1 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

4-2. LOW LIGHT LEVEL FRONT SIGHT. 



This task covers: 

a. DisassetTibly 

b. Inspection 



c. Reassembly 

d. Wrapping and Packaging 



IWITIAL SETUP 

Applicable Configuration 

AN M16/M16A1 Rifles 

Tools 

Front sight post arid low li qiit leve l frorit s ight post 
removal/installation tool 



4»4 



(fiy E 1 app E 



Reference 

Warning page radiatiorn hazard. 

General Safety Instructions 

Low light level sights will be removed from weapons 
that are being transferred or unserviceable or aie 
being disposed. 



Low light level front sight contains radioactive 

material. 
Do not insert metal objects into the post slot o\ other 

wise treat sight roughly to cause breakage of the 

radioactive elemetit. 
Do not eat, drink, or smoke while working on the k")vv 

light level sights. 



a. DISASSEMBLY 



1. Remove low light level fionl siyhl (1) using front slight po:t -.;nd jovf ■;ghl level front ;-,ight post lemoviiig and in 
stallation tool (2). 

2. Catch front sight detent (3) and helical spring (4) to prevent loss. 




4-2 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



b„ INSPECTION 



Visually mspect low light !eve! front sight for broken/or damaged radioac- 
tive element. Inspect manufacturer's data. Replace sight if more than 144 
months have elapsed. Ensure that the rear sight is the rear bw light level 
sight (1). If not, you must have direct support maintenance replace the 
standard rear sight with the rear low light level sight as the sights must 
mate. Ensure the sight is marked with luminous matenal H3. Sights with 
any other lunninous material must be replaced with the appropriate sight. 




c. REASSEMBLY 



1. Install helical spring HI front sight detent (2| and hold in 

position. 

2. install low light level front sight (3) using front sight post 
and low light level front sight post removing and installa- 
tion tool f4K 



d. WRAPPING AND PACKAGING 



1 



ELEMENTS SEES^J 
FROM 2 SiDES Of^LY 



RADIOACTIVE 
CONTENT 9MC 




DATE OF 
MANUFACTURE 



LUMINOUS 

MATERIAL 
H3 



RADIATION 
SYMBOL 



Broken low light level sight post {1} wit! be removed 
and placed in a plastic bag. All defective and/or out- 
dated components will be returned to the storage ac- 
tivity for disposal in accordance with AR 385-1 1. 





{a) Low light level systems that have been removed 
from rifles will be protected by applying a protec- 
tive, chemically-neutral paper conforming to MIL- 
P-17667 (SB 38-100) and placed in a plastic 
bag. 

ib] Final packaging of rear {2) and front HI low light 
level sights wilt be in accordance with instruc- 
tions provided in MIL-STD-1 169, pending possi- 
ble reuse or disposal These packaging criteria are 
furnished since a terminal test for radiation and 
iuminosity will be required. 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST MS370.9 



4-3. LOCK PLATE. 



This task covers: 

a. Installation 

b. Removal 



c. Inspection 



INITIAL SETUP 

Applicable Configuration 
All M16/M16A1 Rifles 

Tools 

Small Arms Repairman Tool Kit 
SC 5180-95-CL-A07 (19204) 



WARNING 



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



a. INSTALLATION 



1 




Using a screwdriver, reach inside rifle grip (1) and 
remove screw (2) and lockwasher (3). 




Carefully remove rifle grip (1). Hold helical spring 
(4) in place. 



4-4 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




NOTE 

Selector lever must be in SAFE or SEMI 
position. 

Install lock plate (5) with the detect helical spring 
passing through the hole in the right side of the 
lockplate, and the arm on the outside of the receiver 
pointing to the SAFE position. 




H i^ g a s cie H lin i, s ! c u is g i 



} |1 ) b f in N llln g 




b. REMOVAL 




I -i 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

4-3. LOCK PLATE (CONT). 



b. REMOVAL (CONT) 




Carefully remove rifle grip (3) and hold helical spring 
(4) in place. 





Still holding helical spring (4) in place, remove 
lockplate (5). 




Using a screwdriver, secure rifle grip (3) with 
lockwasher (2) and screw (1). 



4-6 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



c. INSPECTION 



Inspect tock plate (1) for bends affecting serviceability 
or for missing tang (2). Replace if unserviceable or if 
tang {2) is broken off. 




4-4. TOP SLING ADAPTER. 



This task covers: 




a. Installation 

b. Removal 


c. Inspection 


INITIAL SETUP 




Applicable Configuration 

All M16/M16A1 Rifles 


Reference 

TM 9-1005-249-10 (operator's manual) 


Materials/Parts 

Top sling adapter kit PN 8448471 





a. INSTALLATION 



1 




(a} Refer to operator's manual and remove rifle sling, 

fb) Install top sling adapter strap (1) through sling 
swivel {2) and tie. 




ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



4-4. TOP SLING ADAPTER (CONT), 



a. INSTALLATION (CONT) 





(a) Attach rifle sling (5) to top sling adapter strap (1) and to clamp (31, 

(b) Adjust sling (5). 



b. REMOVAL 



1 




Remove rifle sling (1) from top sling adapter strap (2) 
and clamp (3). 




4-8 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 




(a) Remove clamp (3) from front sight base (5). 

(b) Refer to operator's manual and install rifle sling, 



c. INSPECTION 



Visually inspect top sling adapter strap (1) and 
replace if it is badly worn or damaged. 




4-9 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



4-5. RIFLE BIPOD MS. 



This task covers: 

a. Installation 

b. Removal 



0. Inspection 



INITIAL SETUP 

Applicable Configuration 
All M16/M16A1 Rifles 

Materials/Parts 

Carrying case NSN 1005-00-283-9439 
Rifle biped M3 NSN 1005-00-992-6676 



a. INSTALLATION 



1 



Remove rifle biped M3 (1) from case (2). 




I in la II rille Hp H M (1 |, s q y n ! s b ip H Is p 
h g E th M, s n p u lifls b nie I |1 1, 3 H le It i s e biped 
legs. 




4-10 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



b. REMOVAL 



c. INSPECTION 




1. Squeeze bipod legs (1) together and remove from 
rifle barrel (2). 

2. Install bipod in case. 




1. Visually inspect bipod (1) for bent or broken 
parts. Damaged, broken, or bent bipods should be 
replaced. Bipod must have a good finish. 

2. Inspect bipod case (2) for wear. Badly worn cases 
should be replaced. 



4-6. BLANK FIRING ATTACHMENT M15A2. 



This task covers: 

a. Installation 

b. Removal 

c. Cleaning 












d. Inspection 

e. Repainting 

f. Replacement 


INITIAL SETUP 

Applicable Configuration 
All M16/M16A1 Rifles 

Materials/Parts 

Cleaner, lupTfrani and pr 
(item 9, app D) 


eservative (CLP) 

bore (RBC) 

escent 

(LAW) (item 20, 
(LSA) (item 21, 






General Safety Instructions 

Do not keep live ammunition near the work area. 
Only blank cartridge M200 is to be used when 
the blank firing attachment is attached to the 
rifle. 


(item 11, app D) 


(item 13, app D) 
Lubricating Oil, Weapons 
Lubricating Oil, Weapons 


1 


ZJ 


|app 
app 


I' 



300-1 60-91 -6 



4-11 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



4-6- BLANK FIRIIMG ATTACHMENT Wn5A2 (CONT). | 



a. INSTALLATION 



1 




WARNING 

Do not shoot ob- 
jects with blanks 
closer than 20 
feet. 



Unscrew and pull slide (1) all the way out on blank 

firing attachment (21. 




CAUTION 

Do not use tools to tighten the blank firing 
attachment. USE HANDS ONLY. 

Push slide (11 into flash suppressor (3) and hand 
tighten. 

NOTE 

Check and retighten after firing approximate 
ly 50 blank rounds. 



Lift blank firing attachment (31 up off of flash sup- 
pressor (2). 




Hook blank firing attachment (2) behind the first 
groove of the flash suppressor (3). 



b. REMOVAL 



1 




Unscrew and pull slide (11 all the way out of flash 
suppressor (2). 




4-12 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



c. CLEANING 



Clean blank firing attachment with CLP or RBC, wipe dry, and lubricate with CLP, LSA, or LAW {p2-22). 



d. INSPECTION 



Inspect blank firing attachment for cracks or distortion. Be sure the parts in the slide are clear and clean. If blank 
firing attachment is cracked or distorted, it is unserviceable. 



e. REPAINTING 



Blank firing attachment must be clean and all lubricant must be removed prior to painting. Repaint blank firing at- 
tachment using fluorescent coating compound. Painting is the only repair authorized. 



f. REPLACEMENT 



Replace blank firing attachment if unserviceable. 



Section II. PREPARATION FOR STORAGE OR SHIPMENT 
4-7. PREPARATION FOR SHIPMENT. 

a. Rifles, bipod assemblies, or grenade launchers removed from storage for shipment need not be reprocessed 
unless inspection reveals them to be inadequately preserved, 

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

(1) Clean in accordance with TM. 

(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 1, 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) Fiberboard 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. 

(6) Mark lAW MIL-STD-129. 

4-8. SHIPMENT OF RIFLES TO DEPOT THAT ARE IN EXCESS TO USER. All rifles that are being returned to depot 
that are in excess to user will be returned in serviceable condition, condition code A, if local CATM has the ability to 
repair. (Rifles will be returned with magazine and sling. ) 



4-13 (4-14 blank) 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

APPENDIX A 

REFERENCES 

A-1 . TECHNICAL BULLETINS. 

TB 9-1000-247-34 Standards for Overseas Shipment or Domestic Issue of Small Arms, Aircraft Ar- 
mament, Towed Howitzers, Mortars, Recoilless Rifles, Rocket Launchers and 
Associated Fire Control Equipment 

TB 43-0002-73 Maintenance Expenditures Limits for FSC Group 10; FSC Classes 1005, 1010, 

1015, 1030, 1055, 1090, and 1095 

TB 43-0196 Inspection and Certification of Gages - Small Arms 

A-2. TECHNICAL MANUAL/TECHNICAL ORDERS. 

I TM 9-1005-237 -23SR Unit and Direct Support Maintenance Manual (Including Repair Parts and Special 

Tools List) for Bayonet-Knife M6 and M7, with Bayonet Knife Scabbard M10 

FTM 9-1005-249 - ID ...Operator's Manual for Rifle, 5.56MM, M16 and M16A1 

TM 9-1010-221 -24&P Organizational, Direct Support and General Support Maintenance Manual Including 

Repair Parts and Special Tools List for Launcher, Grenade: 40-mm M203 W/E 
(NSN 1010-00-1 79-6447) 

TM 9-6920 -363 -12&P M261 Conversion Kit 

TM 11-1090-268-13 Operator's, Organizational, and Direct Support Maintenance Manual: Night Vision 

Sight, Individual Served Weapon AN/PVS-1 

TM 750-244-7 Procedures for Destruction of Equipment in Federal Supply Classifications 1000, 

1005, 1010, 1015, 1020, 1025, 1030, 1055, 1090, and 1095 to Prevent 
Enemy Use 

TO00-35D-54 Technical Order, Materiel Deficiency Reporting and Investigating System 

TO11W-1-10 Recording of Inspection, Maintenance, and Firing Date for Ground Weapons 

T011W3-5-5-1 Operator's Manual for Rifle, 5.56 MM, Ml 6 and M16A1 

TO 33K-1-100 Technical Manual (TMDE) Interval Calibration and Repair TO Reference Guide and 

Work Unit Code Manual 

TO 11 A 13-10 -7 Storage and Maintenance Procedures for Small Arms Ammunition 

A-3. ARMY/AIR FORCE REGULATIONS 

AR 385-11 Ionizing Radiation Protection (Licensing, Control, Transportation, Disposal, and 

Radiation Safety) 

AR 700-64 Radioactive Commodities in the DOD Supply System (NAVSUPPUB 5012/AFM 

67-8/MCO P4400. 105/DSAM 41 45.8) 

AFR 50-36 Volume 1 Combat Arms Training and Maintenance Program Management 



A-1 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

A-4. FIELD MANUALS 

FM 21-11 First Aid for Soldiers 

FM 23-9 M16A1 Rifle and Rifle Marksmanship 

A-5. PAMPHLETS 

DA PAM 25-30, Consolidated Index Army Publications and Forms 

DA PAM 738-750, The Army Maintenance Management System (TAMMS) 

A-6. RELATED PUBLICATIONS 

COMDTINST M4855.1 ., Comptroller Manual Volume 10 Quality Assurance 

CTA 8-100 Army Medical Department Expendable/Durable Items 

CTA 50-970 Expendable/Durable Items (Except: Medical, Class V, Repair Parts and Heraldic 

Items) 

MIL-STD-1169 Packaging, Packing and Marking for Shipment to Inert Ammunition Components 

MIL-B-121 Barrier Material, Greaseproofed, Waterproofed, Flexible (NSN 8135-00-753-4661) 

MIL-B-117 Bag, Sleeve and Tubing-interior Packaging (NSN 8135-00-543-6574) 

PPP-B-636 Boxes, Shipping, Fiberboard 

PPP-B-601 Boxes, Wood, Cleated Plywood 

MIL-STD-129 Marking for Shipment and Storage 

PPP-T-76 Tape, Packaging, Paper 

MIL-STD-1186 . ., ., Cushioning, Anchoring, Bracing, Blocking and Waterproofing; with appropriated 

test methods 

PPP-C-843 Cushioning Material, Cellulosic 

PPP-F-320 Fiberboard, Corrugated and Solid Sheet Stock (Container Grade), and Cut Shapes 

PPP-B-640 Boxes, Fiberboard, Corrugated, Triple-Wall 

PPP-B-621 Boxes, Wood, Nailed and Locked-Corner 

SPI 00-856-6885 Special Packaging Instructions 

A-7. SUPPLY CATALOGS. 

SC 5180-95-CL-A07 Small Arms Repairman Tool Kit 

SC 4933-95-CL-A1 1 Field Maintenance Basic Less Power Small Arms Shop Set 



A-2 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

APPENDIX B 
MAINTENANCE ALLOCATION CHART 
Section 1. INTRODUCTION 
B-1 . GENERAL. 

a. This section provides a general explanation of all maintenance and repair functions authorized at various mainte- 
nance categories. 

b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibility for the per- 
formance of maintenance functions on the identified end item or component. The application of the maintenance func- 
tions to the end item or component will be consistent with the capacities and capabilities of the designated mainte- 
nance categories. 

c. Section III lists the tools and test equipment (both special tools and common tool sets) required for each mainte- 
nance function as referenced from section II. 

d. Section IV contains supplemental instructions and explanatory notes for a particular maintenance function. 

B-2. MAINTENANCE FUNCTIONS. Maintenance functions will be limited to and defined as follows: (except for am- 
munition MAC). 

a. Inspect. To determine the serviceability of any item by comparing its physical, mechanical, and/or electrical char- 
acteristics with established standards through examination (e.g., by sight, sound, or feel). 

b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of 
an item and comparing those characteristics with prescribed standards. 

c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean (includes 
decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or 
gases. 

d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or by setting 
the operating characteristics to specified parameters. 

e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance. 

f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measuring 
and diagnostic equipments used in precision measurement. Consists of comparison of two instruments, one of which 
is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument be- 
ing compared. 

NOTE 



Air Force Precision Measurement Equipment Laboratory (PMEL) person will calibrate 
small arms inspection gages in accordance with TO 33K-1 -100. 

g. Remove/Install. To remove and install the same item when required to perform service or other maintenance 
functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (compo- 
nent or assembly) in a manner to allow the proper functioning of an equipment or system. 

h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is author- 
ized by the MAC and is shown as the 3d position code of the SMR code. 



'Exception is authorized for ammunition MAC to permit the redesignation/redefinition of maintenance function 
headings to more adequately identify ammunition maintenance functions. The, heading designations and definitions will 
be included in the appropriate technical manual for each category of ammunition. 



B-1 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST IUI8370.9 

i. Repair. The application of maintenance services', including fault location/troubleshooting', removal/installation, 
and disassembly/assembly' procedures, and maintenance actions to identify troubles and restore serviceability to an 
item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or 
assembly), end item, or system. 

j. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/opera- 
tional condition as required by maintenance standards in appropriate technical publications (i. e., DMWR). Overhaul is 
normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like 
new condition. 

k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new 
condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance 
applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements 
(hours/miles, etc. ) considered in classifying Army equipment/components. 

B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II. 

a. Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to identify 
maintenance significant components, assemblies, subassemblies, and modules with the next higher assembly. End 
item group number shall be "00. " 

b. Column 2, Component/Assembly. Column 2 contains the names of components, assemblies, subassemblies, and 
modules for which maintenance is authorized. 

c. Column 3, Maintenance Function. Column 3 lists the functions to be performed on the item listed in column 2. 
(For detailed explanation of these functions, see | paragraph 6-27] ) 

d. Column 4, Maintenance Level. Column 4 specifies, by the listing of a work time figure in the appropriate sub- 
column(s), the level of maintenance authorized to perform the function listed in column 3. This figure represents the 
active time required to perform that maintenance function at the indicated level of maintenance. If the number or 
complexity of the tasks within the listed maintenance function vary at different maintenance levels, appropriate work 
time figures will be shown for each level. The work time figure represents the average time required to restore an 
item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field 
operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), 
troubleshooting/fault location time, and quality assurance/quality control time in addition to the time required to per- 
form the specific tasks identified for the maintenance functions authorized in the maintenance allocation chart. The 
symbol designations for the various maintenance levels are as follows: 

C . . . Operator or Crew H . General Support Maintenance 

O Unit Maintenance L Specialized Repair Activity (SPA)' 

F Direct Support Maintenance D . Depot Maintenance 



Services — inspect, test, service, adjust, align, calibrate, and/or replace. 

Fault tocate/troubleshoot — The process of investigating and detecting the cause of equipment malfunctioning; the 
act of isolating a fault within a system or unit under test (UUT). 

Disassemble/assembly — encompasses the step-by-step taking apart (or breakdown) of a spare/functional group 
coded item to the level of its least componency identified as maintenance significant (i. e., assigned as SMR code) for 
the category of maintenance under consideration. 

Actions — welding, grinding, riveting, straightening, facing, remachining, and/or resurfacing. 

This maintenance level is not included in Section 11, column (4) of the Maintenance Allocation Chart. To identify 
functions to this level of maintenance, enter a work time figure in the "H" column of Section 11, column (4), and use 
an associated reference code in the Remarks column (6). Key the code to Section IV, Remarks, and explain the SRA 
complete repair application there. The explanatory remark(s) shall reference the specific Repair Parts and Special Tools 
List (RPSTL) TM which contains additional SRA criteria and the authorized spare/repair parts. 



B-2 



ARMY TM 9-100-249-23&P 

AIR-FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

e. Column 5, Tools and Equipment. Column 5 specifies, by code, those common tool sets (not individual tools) 
and special tools, TMDE, and support equipment required to perform the designated function. 

f. Column 6, Remarks. This column shall, when applicable, contain a letter code, in alphabetic order, which 
shall be keyed to the remarks contained in Section IV. 

B-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION III. 

a. Column 1, Reference Code. The tool and test equipment reference code correlates with a code used in the 
MAC, section II, column 5. 

b. Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment. 

c. Column 3, Nomenclature. Name or identification of the tool or test equipment. 

d. Column 4, National Stock Number. The National stock number oft he tool or test equipment 

e. Column 5, Tool Number. The manufacturer's part number, 
B-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV. 

a. Column 1, Reference Code The code recorded in column 6, Section II. 

b. Column 2. Remarks. This column lists information pertinent to the maintenance function being performed as 
indicated in the MAC, section II. 



B-3 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



Section II. MAINTENANCE ALLOCATION CHART 

FOR 

M16/M16A1 RIFLE 



(1) 


(2) 


(3) 






(41 


(51 


(61 










Maintenance Level 


Tools 








Direct 


General 




Group 
Number 


Component/ 
Assembly 


Maintenance 
Function 


Unit 


Support 


Support 


Depot 


and 
EQPT 


Remarks 


C 





F 


H 


D 


00 


M16/M16A1 RIFLE 


Inspect 

Test 

Service 

Replace 

*Overhaul 


0.1 
0.2 


0.2 

0.3 

0.1 


0.3 
0.3 






3 




01 


BOLT CARRIER 
ASSEMBLY 


Inspect 

Test 

Service 

Remove/ 

Install 

Replace 

Repair 


0.1 

0.1 
0.1 


0.1 
0.1 

0.1 


0.1 
0.1 

0.1 
0.2 






3 
2 




0101 


Bolt Assembly 


Inspect 
Test 

Service 

Remove/ 

Install 

Replace 

Repair 


0.1 

0.1 
0.1 


0.1 
0.1 

0.2 


0.1 
0.1 

0.1 
0.2 






3 
2 




0102 


Key and Bolt 
Carrier Assembly 


Inspect 
Service 
Replace 


0.1 
0.1 


0.1 


0.1 
0.2 






1,2 








Repair 




0.1 


0.2 






1,3 


A 


02 


CHARGING HANDLE 
ASSEMBLY 


Inspect 
Service 
Remove/ 

Install 

Replace 

Repair 


0.1 
0.1 
0.1 


0.1 
0.1 

0.1 
0.1 








2 





*Worl< items Tor Depot Overhaul are not included 



B-4 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



Section II. MAINTENANCE ALLOCATION CHART 

FOR 

M16/M16A1 RIFLE (Continued) 



(1) 


(2) 


(3) 




(4) 


{51 


(6) 








Maintenance Level 


Tools 






Direct 


General 




Group 
Number 


Component/ 

Assembly 


Maintenance 
Function 


Unit 


Support 


Support 


Depot 


and 

EQPT 


Remarks 


C 


Q 


F 


H 


D 


03 


UPPER RECEIVER AND 
BARREL ASSEMBLY 


Inspect 

Test 

Service 

Remove/ 

Install 

Replace 


0.1 

0.2 

0.1 


0.2 
0.2 


0.1 
0.2 

1.2 






2 

1,2,3,4 








Repair 




0.5 


0.5 






1,2,3 


B 


0301 


Rifle Barrel Assembly 


Replace 
Remove/ 

Install 






0.5 
0.2 






2,3,4 




0302 


Upper Receiver 
Assembly 


Inspect 
Replace 
Repair 






0.1 
0.5 
0.3 






2,3,4 
3,4 




030201 


Forward Assist 
Assembly 


Inspect 

Remove/ 

Install 

Replace 

Repair 

Service 






0.1 
0.2 

0.2 
0.2 

0.1 






3 

3 

3 
3 




04 


LOWER RECEIVER AND 


Inspect 


0.1 


0.2 


0.2 












EXTENSION ASSEM- 


Test 






0.1 






3 


E 




BLY 


Service 


0.2 


0.2 
















Repair 




0.3 


0.3 






2,3,6 


C 


0401 


Buttstock Assembly 


Inspect 

Remove/ 

Install 

Replace 

Repair 

Service 




0.1 
0.1 

0.1 

0.1 


0.1 






3 

3 
3 




0402 


Hammer Assembly 


Inspect 
Remove/ 
Install 
Replace 






0.1 
0.1 

0.1 
0.1 






3 

3 
3 





B-5 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



Section II. MAINTENANCE ALLOCATION CHART 

FOR 

M16/M16A1 RIFLE (Continued) 



(1) 

Group 
Number 


(2) 

Component/ 
Assembly 


(3) 

Maintenance 
Function 


(4) 
Maintenance Level 


(5) 

Tools 

and 

EQPT 


(6) 
Remarks 


Unit 


Direct 
Support 


General 
Support 


Depot 


C 


O 


F 


H 


D 


0403 


Trigger Assembly 


Inspect 

Remove/ 

Install 

Replace 

Repair 






0.1 
0.1 

0.1 
0.1 






3 

3 
3 




0404 


Lower Receiver and 
Extension Subassembly 


Inspect 

Test 

Repair 






0.1 
0.1 
0.3 


0.1 




3,6 

3 


D 



Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS 

FOR 
M16/M16A1 RIFLE 



(1) 


(2) 


(3) 


(41 


(51 


Tool/Test 










Equipment 


Maintenance 




National/NATO 




Ref. Code 


Level 


Nomenclature 


Stock Number 


Tool Number 


1 


F 


Shop Set, Small Arms; Field 
Maintenance, Basic Less 
Power 


4933-00-754-0664 


SC4933-95-CL-A11 


2 


F 


Tool and Gage Set DS/GS 
Maintenance for 5.56mm Rifle, 
M 16 Series 


4933-00-056-7106 


8426685 


3 


0,F 


Tool Kit, Small Arms 
Repairman 


5180-00-357-7770 


SC 5180-95-CL-A07 


4 


F 


Torque Wrench ft. lb 


5120-00-640-6365 


Part of Army Tool 
Set 


5 


F 


Torque Wrench in. lb. 


5120-00-230-6380 


Part of Army Tool 
Set 


6 


F 


Trigger Weights 


4933-00-647-3696 


Part of Army Tool 
Set 



Section IV. REMARKS 



REFERENCE CODE REMARKS 



Tool, Key 

Tool, Sight Remover 

Tool, Pivot Pin Removing 

Only direct support level maintenance is authorized to restamp serial numbers 

Lower Receiver Go-No Go Gage 



B-6 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



APPENDIX C 

UNIT AND DIRECT SUPPORT MAINTENANCE 

REPAIR PARTS AND SPECIAL TOOLS LIST 

(INCLUDING DEPOT MAINTENANCE REPAIR PARTS) 



section I. INTRODUCTION 

c-1. SCOPE. This RPSTL lists and authorizes spares and repair parts; special tools; special test, measure- 
ment, and diagnostic equipment (TMDE); and other special support equipment required for performance of 
unit and direct support maintenance of the rifle. It authorizes the requisitioning, issue, and disposition of 
spares, repair parts, and special tools indicated by the Source, Maintenance, and Recoverability (SMR) 
codes. 

C-2. GENERAL. In addition to Section I, Introduction, this Repair Parts and Special Tools List is divided 
into the following sections: 

a. Section II. Repair Parts List. A list Of spares and repair parts authorized by this RPSTL for use in 
the performance of maintenance. The list also includes parts which must be removed for replacement of the 
authorized parts. Parts lists are composed of functional groups in ascending alphanumeric sequence, with 
the parts in each group listed in ascending figure and item number sequence. Bulk materials are listed by 
item name in FIG. BULK at the end of the section. Repair parts kits are listed separately in their own 
functional group within section II. Repair parts for repairable special tools are also listed in this section. 
Items listed are shown on the associated illustration(s)/figure(s). 

b. Section III. Special Tools List. A list Of special tools, special TMDE, and other special support, equip- 
ment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in DESCRIPTION AND 
USABLE ON CODE column) for the performance of maintenance. 

c. Section IV. Cross-Reference Index. A list. In National item identification number (NUN) sequence, of all 
National stock numbered items appearing in the listing, followed by a list in alphanumeric sequence of all 
part numbers appearing in the listings. National stock numbers and part numbers are cross-referenced to 
each illustration figure and item number appearance. The figure and item number index lists figure and 
item numbers in alphanumeric sequence and cross-references NSN, FSCM and part numbers. 

C-3. EXPLANTION OF COLUMNS (SECTIONS II AND III). 

a. ITEM NO. (Column (1)). Indicates the number used to identify items called out in the illustration. 

b. SMR Code (Column (2)). The Source, Maintenance, and Recoverability (SMR) code is a 5-position code 
containing supply/requisitioning information, maintenance level authorization criteria, and disposition in- 
structions, as shown in the following breakout. 



c-i 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST 



M8370. 



Source 
Code 



Maintenance 
Code 



Recoverability 
Code 



XX 



1st two 
positions 



XX 



X 



5th 
position 



How vou eet an item 



3d position 

Who can install 
replace or use 
the item 



4th position 

Who can do 
complete repair* 
on the item 



Who determines dispo- 
sition action on un- 
serviceable item 



^Complete Repair: Maintenance capacity, capability, and authority to perform all corrective maintenance 
tasks of the "Repair" function in a use/user environment in order to restore serviceability to a failed item. 

(1) Source Code . The source code tells you how to get an item needed for maintenance, repair, or over- 
haul of an end item/equipment. Explanations of source codes follows: 



Code 



PA 
PB 

PD 
PE 
PF 
PG 



> 



Explanation 



Stocked items; usetheapplicableNSN to request/requisition items 
with these source codes. They are authorized to the level indicated 
by the code entered in the 3d position of the SM R code. 

**N GTE Items coded PC are subject to deterioration. 



KD 

KF 
KB 



Items with these codes are not to be requested /requisitioned individually. 
They are part of a kit which is authorized to the maintenance level 
indicated in the 3d position of the SMR code. The complete kit must be re- 
quisitioned and applied. 



MO 



(Made at Unit 
AVUM Level) 
(Made at 

DS/AVIJVI 

Level) 
(M ade at 
GS Level) 
(Made at Spe- 
cialized Repair 
Act (SRA) 
MD - (Made at Depot) 



MF 



MH 



ML 



> 



Items with these codes are not to be requested/requisitioned in- 
dividually. They must be made from bulk material which is iden- 
tified by the part number in the DESCRIPTION AND USABLE 
ON CODE (UOC) column and listed in the bulk material group of 
the repair parts list in this RPSTL. If the item is authorized to you 
by the 3d position code of the SM R code, but the source code in- 
dicates it is made at a higher level, order the item from the higher 
level of maintenance. 



C-2 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



Code Explanation 



AO - (Assembled by unit/ Items with these codes are not to be requested/requisitioned 

AVUM I^vel) individually. The parts that make up the assembled item must be 

AF - (Assembled by ! requisitiond or fabricated and assembled at the level of mainte- 

DS/AVIM Level) V nance indicated by the source code. If the 3d position code of the 

AH - (Assembled by / SMR code authorizes you to replace the item, but the source 
GS Level) code indicates the item is assembled at a higher level, order the 

AL - (Assembled by SRA) item from the higher level of maintenance. 

AD - (Assembled by Depot) 



XA - Do not requisition an "XA' '-coded item. Order its next higher assembly. (Also, refer to the NOTE 
below.) 

XB - If an "XB" item is not available from salvage, order it using the FSCM and part number given. 

XC - Installation drawing, diagram, instruction sheet, field service drawing, that is identified by manufac- 
turer's part number. 

XD - Item is not stocked. Order am "XD' '-coded item through normal supply channels using the FSCM and 
part number given, if no NSN is available. 

NOTE; Cannibalization or controlled exchange, when authorized, may be used as a source of supply for 
items with the above source codes, except for those source coded "XA" or those aircraft support items 
restricted by requirements of AR 700-42. 

(2) Maintenance Code . Maintenance codes tell you the level(s) of maintenance authorized to USE and 
REPAI R support items. The maintenance codes are entered in the third and fourth positions of the SMR 
code as follows 

(a) The maintenance code entered in the third position tells you the lowest maintenance level authoriz- 
ed to remove, replace, and use an item. The maintenance code entered in the third position will indicate 
authorization to one of the following levels of maintenance. 

Code Application/ Explanation 

c Crewor operator maintenance done within unit or aviation unit maintenance. 

Unit or aviation unit level can remove, replace, and use the item. 

F Direct support or aviation level can remove, replace and use the item. 

H General support level can remove, replace, and use the item. 

L Specialized repair activity can remove, replace, and use the item. 

D Depot level can remove, replace, and use the item. 

(b) The maintenance code entered in the fourth position tells whether or not the item is to be repaired 
and identifies the lowest maintenance level with the capability to do complete repair (i.e., perform all 
authorized repair functions), (note: Some limited repair may be done on the item at a lower level of 
maintenance, if authorized by the Maintenance Allocation Chart (MAC) and SMR codes.) This position will 
contain one of the following maintenance codes. 



C-3 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

Code Application/ Explanation 

Unit or aviation unit is tlie lowest level that can do complete repair of the item. 

F Direct support or aviation is the lowest level that can do complete repair of the item. 

H General support is the lowest level that can do complete repair of the item. 

L Specialized repair activity (designate the specialized repair activity) is the lowest level that 

can do complete repair of the item. 

D Depot is the lowest level that can do complete repair of the item. 

Z N onreparable. No repair is autliorized. 

B No repair is authorized. No parts or special tools are authorized for the maintenance of a 

"B" coded item. However, the item may be reconditioned by adjusting, lubricating, etc., 
at the user level. 

(3) Recoverability Code . Recoverability codes are assigned to items to indicate the disposition action 
on unserviceable items. The recoverability code is entered in the fifth position of theSMR Code as follows: 

Recoverability 

Code Application/ Explanation 

Z N onreparable item. When unserviceable, condemn and dispose of the item at the level of 

maintenance shown in 3d position of SMR Code. 

Reparable item. When uneconomical ly reparable, condemn and dispose of the item at unit 

or aviation unit level. 

F Reparable item. When uneconomically reparable, condemn and dispose of the item at the 

direct support or aviation level. 

H Reparable item. When uneconomically reparable, condemn and dispose of the item at the 

general support. 

D Reparable item. When beyond lower level repair capability, return to depot. Condemnation 

and disposal of item not authorized below depot level. 

L Reparable item. Condemnation and disposal not authorized below specialized repair activi- 

ty (SRA). 

A Item requires special handling or condemnation procedures because of specific reasons 

(e.g., precious metal content, high dollar value, critical material, or hazardous material). 
Refer to appropriate manuals/directives for specific instructions. 



C-4 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

c. FSCM (Column (3)). The Federal Supply Code for Manufacturer (FSCM) is a 5-digit numeric code which 
is used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item. 

d. PART NUMBER (Column (4)). I ndlcates the primary number used by the manufacturer (individual, 
company, firm, corporation, or Government activity), which controls the design and characteristics of the 
item by means of its engineering drawings, specifications standards, and inspection requirements to identify 
an item or range of items. 

NOTE: When you use a NSN to requisition an item, the item you receive may have a different part number 
from the part ordered. 

e. DESCRIPTION AND USABLE ON CODE (UOC) (Column (5)). This column includes the following 
information: 

(l)The Federal item name and, when required, a minimum description to identify the item. 

(2) Spare/repair parts that make up an assembled item are listed immediately following the assembled 
item line entry. 

(3) NSNs for bulk materials are referenced in this column in the line item entry for the item to be 
manufactured/fabricated. 

(4) When the item is not used with all serial numbers of the same model, the effective serial numbers 
are shown on the last lines of the description (before UOC). 



(5) The usable on code, when applicable (see l paragraph C-5,| special information 



(6) In the Special Tools List section, the basis of issue (BOI) appears as the last line(s) in the entry for 
each special tool, special TMDE, and other special support equipment. When density of equipments sup- 
ported exceeds density spread indicated in the basis of issue, the total authorization is increased 
proportionately. 

(7) The statement "END OF FIGURE" appears just below the last item description in column 5 for a 
given figure in both section II and section III 

f. QTY (Column (6)). The QTY (quantity per figure column) indicates the quantity of the item used in the 
breakout shown on the illustration figure, which is prepared for a functional group, subfunctional group, or 
an assembly. A "V" appearing in this column in lieu of a quantity indicates that the quantity is variable 
and the quantity may vary from application to application. 



C-5 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

C^. EXPLANATION OF COLUMNS (SECTION IV). 

a. National Stock Number (NSN) Index. 

(1) STOCK NUMBER column . This column lists the NSN by National item identification number 
(NIIN) sequence. The NIIN consists of the last nine digits of the NSN 

NSN 

(i.e., 5385 -01-574-147 6). When using this column to locate an item, ignore the first 4 digits of the 

NIIN 
NSN. However, the complete NSN should be used when ordering items by stock number. 

(2) FIG, column . This column lists the number of the figure where the item is identified/located. 
The figures are in numerical order in section II and section III. 

(3) ITEM column. The item number identifies the item associated with the figure listed in the adjacent 
FIG. column. This item is also identified by the NSN listed on the same line. 

b. PART NUMBER INDEX. Part numbers in this index are listed by part number in ascending alpha- 
numeric sequence (i.e., vertical arrangement of letter and number combination which places the first letter 
or digit of each group in order A through Z, followed by the numbers O through 9 and each following letter 
or digit in like order). 

(1) FSCM column . The Federal Supply Code for Manufacturer (FSCM) is a 5-digit numeric code used 
to identify the manufacturer, distributor, or Government agency, etc., that supplies the item. 

(2) PART NUMBER column. Indicates the primary number used by the manufacturer (individual, firm, 
corporation, or Government activity), which controls the design and characteristics of the item by means of 
its engineering drawings, specifications standards, and inspection requirements to identity an item or range 
of items. 

(3) STOCK NUMBER column . This column lists the NSN for the associated part number and manufac- 
turer identified in the PART NUMBER and FSCM columns to the left. 

(4) FIG, column . This column lists the number of the figure where the item is identified/located 
in sections II and III. 

(5) ITEM column . The item number is that number assigned to the item as it appears in the figure 
referenced in the adjacent figure number column. 

c. Figure and Item Number Index. 

(1) FIG, column . This column lists the number of the figure where the item is identified/located in 
section II and III. 

(2) ITEM column . The item number is that number assigned to the item as it appears in the figure 
referenced in the adjacent figure number column. 

(3) STOCK NUMBER column. This column lists the NSN for the item. 



C-6 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

(4) FSCM column . The Federal Supply Code for Manufacturer (FSCM) is a 5-digit numeric code used 
to identify the manufacturer, distributor, or Government agency, etc., that supplies the item. 

(5) PART NUMBER column. Indicates the primary number used by the manufacturer (individual, 
firm, corporation, or Government activity), which controls the design and characteristics of the item by 
means of its engineering drawings, specifications standards, and inspection requirements to identify item 
or range of items. 

C-5. SPECIAL INFORMATION. 

a. Usable on Code , The usable on code appears in the lower left comer of the DESCRIPTION column 
heading. Usable on codes are shown as "UOC..." in DESCRIPTION column (justified left) on the first 
line applicable item description/nomenclature. Uncoded items are applicable to all models. Identification 
of the usable on codes used in the RPSTL are: 

Code Used On 

755 M16 

194 M16A1 

b. Assembly Instructions , Detailed assembly instructions for items source coded to be assembled from 
component spare/repair parts are found in |cnapter 5\ Items that make up the assembly are listed im- 



mediately following the assembly item entry or reference is made to an applicable figure. 

c. Index Numbers , Items which have the word BULK in the figure column will have an index number 
shown in the item number column. This index number is a cross-reference between the National Stock 
Number/Part Number index and the bulk material list in section II. 

C-6, HOW TO LOCATE REPAIR PARTS, 
a. When National Stock Number or Part Number is Not Known , 

(1) First . Using the table of contents, determine the assembly group or subassembly group to which 
the item belongs. This is necessary since figures are prepared for assembly groups and subassembly 
groups, and listings are divided into the same groups. 

(2) Second. Find the figure covering the assembly group or subassembly group to which the item 
belongs. 

(3) Third. Identify the item on the figure and note the item number. 

(4) Fourth , Refer to the Repair Parts List for the figure to find the part number for the item number 
noted on the figure. 

(51 Fifth, Refer to the Part Number Index to find the NSN, if assigned. 



C-7 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

b. When National Stock Number or Part Number is Known. 

(1) First. Using the index of National stock numbers and part numbers, find the pertinent National 
stock number or part number. The NSN index is in National Item Identification Number (N I IN) se- 
quence (see C-4a(l)). The part numbers in the PART NUMBER INDEX are listed in ascending 
alphanumeric sequence (see C-4b). Both indexes cross-reference you to the illustration/figure and item 
number of the item you are looking for. 

(2) Second . Turn to the figure and item number, verify that the item is the one you're looking for, 
then locate the item number in the repair parts list for the figure. 

C-7. ABBREVIATIONS. Not applicable. 



C-8 



SECTION 



TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD CMDTINST M8370.9 



Section II. REPAIR PARTS LIST 
7 




M16A1 



Figure C-1. 5. 5 6MM Rifle M16. 8448600 and MlGAl. 844'8'^(T0: 



(1) 


(2) 


(3) 


(4) 


:tem 


SMR 




PART 


NO 


CODE 


CAGEC 


Number 



(5) (6) 

DESCRIPTION AND USABLE ON CODES (UOC) QTY 

GROUP 00 FIG C-1 
5.56MM RIFLE M16 (8448600) 
AND M16A1 (8448500) 



1 AFFFF 19204 8448501 

2 PAOOO 19204 8448517 

3 AFFFF 19204 8448601 

3 AFFFF 19204 8448522 



4 PACZZ 19200 8448670 

5 PACZZ 19204 12624561 

6 XAFFA 19204 8448604 



6 XAFFA 19204 8448578 



BOLT CARRIER ASSEMBLY (SEE FIG.C-2 

FOR BREAKDOWN) 

HANDLE ASSEMBLY, CHARGING (SEE FIG 
C-5 FOR BREAKDOWN ).._.._._._^ l.*^ • " 

UPPER RECEIVER AND BARREL ASSEMBLY" 

M16, (SEE FIG.C-6 FOR BREAKDOWN) . . . . 

UOC:755 

UPPER RECEIVER AND BARREL ASSEMBLY, 

M16A1 (SEE FIG.C-6 FOR BREAKDOWN) . . . 

UOC: 194 

MAGAZINE, CARTRIDGE 

SLING,SMALL ARMS 

LOWER RECEIVER AND EXTENSION ASSY, 
M16 (SEE FIG C-10 FOR BREAKDOWN) . . . . 
UOC: 755 

LOWER RECEIVER AND EXTENSION ASSY, 
M16A1 (SEE FIG C-10 FOR BREAKDOWN) . . 
UOC: 194 

END OF FIGURE 



C-1-1 



SECTION II 



TM 9-1005-249-23&P 

AIR FORCE TO llW-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




Figure C-2. Bolt Carrier Assembly 8448501 



(1) 


(2) (3) 


(4) 


:tem 


SMR 


PART 


NO 


CODE CAGEC 


NUMBER 



(5) (6) 

DESCRIPTION AND USABLE ON CODES (UOC) QTY 



GROUP 01 FIG C-2 
BOLT CARRIER ASSEMBLY 8448501 



1 PAFZZ 19204 8448503 

2 PAOZZ 19204 8448504 

3 PAOZZ 19204 8448502 

4 PAFFF 19200 8448509 

5 AFFFF 19204 8448505 



PIN, FIRING 1 

PIN, FIRING PIN RETAINING 1 

P IN .GROOVED, HEADED 1 

BOLT ASSEMBLY (SEE FIG C-3 FOR 1 

BREAKDOWN) 

KEY AND BOLT CARRIER ASSEMBLY (SEE 1 

FIG. C-4 FOR BREAKDOWN) 



END OF FIGURE 



C-2-1 



SECTION II 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




Figure C-3 . Bolt Assembly 8448509. 



(1) 


(2) 


(3) 


(4) 


ITEM 


SMR 




PART 


NO 


CODE 


CAGEC 


NUMBER 



(5) (6) 

DESCRIPTION AND USABLE ON CODES (UOC) QTY 

GROUP 0101 FIG C-3 
BOLT ASSEMBLY 8448509 



1 PAFZZ 19204 8448511 


RING, BOLT 


, , , , 3 


2 XAFZZ 19204 8448510 


BOLT 


1 1 1 1 1 


3 PAOZZ 19204 8448513 


PIN,EXTRACTOR 


... I 


4 PAOZZ 96906 MS16562-98 


PIN, SPRING 




5 PAOZZ 19204 8448516 


SPRING, HELICAL 


... I 


6 PAOZZ 19204 8448515 


EJECTOR, CARTRIDGE 




7 PAOZZ 19204 8448512 


EXTRACTOR, CARTRIDGE 




8 PAOZZ 19200 8448755 


SPRING ASSEMBLY, EXT EXTRACTOR . . . . 


• • I 



END OF FIGURE 



C-3-1 



SECTION II 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




Figure C-4. Key and Bolt Carrier Assembly 8448505. 



(1) 


(2) 


(3) 


(4) 


ITEM 


SMR 




PART 


NO 


CODE 


CAGEC 


NUMBER 



(5) (6) 

DESCRIPTION AND USABLE ON CODES (UOC) QTY 

GROUP 0102 FIG C-4 

KEY AND BOLT CARRIER ASSEMBLY 

8448505 



1 PAFZZ 19204 8448508 

2 PAFZZ 19200 8448506 

3 PAFZZ 19200 8448507 



SCREW, CARRIER AND KEY 
KEY, BOLT CARRIER . . . . 
CARRIER, BOLT 



END OF FIGURE 



C-4-1 



SECTION II 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




Figure C-5. Charging Handle Assembly 8448517. 



(1) 


(2) (3) 


(4) 


:tem 


SMR 


PART 


NO 


CODE CAGEC 


NUMBER 



(5) (6) 

DESCRIPTION AND USABLE ON CODES (UOC) QTY 

GROUP 02 FIG C-5 
CHARGING HANDLE ASSEMBLY 8448517 



1 PAOZZ 13629 8448521-2 

2 PAOZZ 19204 8448520 

3 PAOZZ 19200 8448519 

4 XAOZZ 19204 8448518 



PIN, SPRING 

SPRING, HELICAL 

LATCH, CHARGING HANDLE 
HANDLE 



END OF FIGURE 



C-5-1 



SECTION II 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




Figure C-6. Upper Receiver and Barrel Assembly M16, 8448601 and M16A1, 8448522. 



SECTION II 



TM9-1005-249-23SP 

AIR FORCE TO llW-3-5-5-24 

COAST GUARD CMDTINST M8370.9 



(1) 


(2) 


(3) 


(4) 


ITEM 


SMR 




PART 


NO 


CODE 


CAGEC 


NUMBER 



(5) 



DESCRIPTION AND USABLE ON CODES (UOC) 



(6) 



QTY 



GROUP 03 FIG C-6 

UPPER RECEIVER AND BARREL ASSEMBLY 

H16 (8448601) AND M16A1 (8448522) 



2 


PAFZZ 


19200 


8448567 




3 


PAOZZ 


19200 


9349059 




4 


PAFFF 


19204 


8448663 




5 


PAFZZ 


19204 


8448576 




6 


PAFZZ 


19204 


8448577 




7 


PAFZZ 


96906 


MSI 6 5 62- 


-106 


8 


PAFZZ 


19204 


8448712 




9 


PAFZZ 


19204 


8448712 




10 


PAFZZ 


96906 


MS16626- 


-1137 



UPPER RECEIVER ASSY,M16 (SEE FIG.C- 

8 FOR BREAKDOWN) 

UOC;755 

UPPER RECEIVER ASSY,M16A1 (SEE 

FIG.C-8 FOR BREAKDOWN) 

UOC: 194 

TUBE, GAS 

HANDGUARD ASSEMBLY 

BARREL ASSEMBLY, RIFLE (SEE FIG C- 

7 FOR BREADKDOWN) 

SUPPRESSOR, FLASH 

WASHER, LOCK, FLASH SUPPRESSOR 

PIN, SPRING 

RING, SLIP, HAND GUAR GUARD 

SPRING, SLIP RING, HANDGUARD 

RING, RETAINING EXT, TAPERED SECTION 



END OF FIGURE 



SECTION II 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 



-(£■ 



^^ 




r^i£ 



p—^ 



Figure C-7. Rifle Barrel Assembly 8448663. 



(1) 


(2) (3) 


(4) 


ITEM 


SMR 


PART 


NO 


CODE CAGEC 


NUMBER 



1 


PAOZZ 


19200 


9349056 


2 


PAOZZ 


19204 


8448573 


3 


PAOZZ 


19204 


8448574 


4 


PAOZZ 


19204 


8448571 


5 


PAOZZ 


19204 


8448697 



(5) (6) 

DESCRIPTION AND USABLE ON CODES (UOC) QTY 

GROUP 0301 FIG C-7 
RIFLE BARREL ASSEMBLY 8448663 



POST, FRONT SIGHT . , 
DETENT, FRONT SIGHT 
SPRING, HELICAL . . . 
SWIVEL, SLING, SMALL 
RIVET, TUBULAR . . . . 



END OF FIGURE 



C-7-1 



SECTION II 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




Figure C-8. Upper Receiver Assembly M 16, 8448602 and M16A1, 8448523. 



SECTION II 



TM9-1005-249-23SP 

AIR FORCE TO llW-3-5-5-24 

COAST GUARD CMDTINST M8370.9 



(1) 


(2) 


(3) 


(4) 


ITEM 


SMR 




PART 


NO 


CODE 


CAGEC 


NUMBER 



(5) 



DESCRIPTION AND USABLE ON CODES (UOC) 



(6) 



QTY 



GROUP 0302 FIG C-8 

UPPER RECEIVER ASSEMBLY 

H16 (8448602) AND M16A1 (8448523) 



1 


PAFZZ 


19204 


8448603 


1 


PAFZZ 


19200 


12576280 


2 


PAOZZ 


96906 


MS16632-1012 


3 


PAOZZ 


19204 


8448533 


4 


PAOZZ 


19204 


8448525 


5 


PAOZZ 


19204 


8448532 


6 


PAFZZ 


96906 


MS 16562-121 


7 


PAFZZ 


19200 


8448540 


8 


AFFFF 


19204 


9349086 



9 


PAFZZ 


19200 


8448535 


10 


PAFZZ 


96906 


MS 16562-96 


11 


PAFZZ 


19200 


8448537 


12 


PAFZZ 


19200 


8448538 


13 


PAFZZ 


19200 


8448536 


14 


PAFZZ 


19204 


8448539 


15 


PAFZZ 


19204 


8448534 



RECEIVER, UPPER Ml 6 

UOC:755 

RECEIVER, CARTRIDGE M16A1 

UOC: 194 

RING, RETAINING 

PIN, GROOVED, HEADLES COVER 

COVER, EJECTION 

SPRING, HELICAL 

PIN, SPRING (FORWARD ASSIST PIN) 

UOC: 194 

SPRING, HELICAL, COHP COMPRESSION 

UOC: 194 

FORWARD ASSIST ASSY (SEE FIG.C-9 

FOR BREAKDOWN) 

UOC: 194 

DIAL, CONTROL WINDAGE 

PIN, SPRING 

DETENT, REAR SIGHT 

SPRING, HELICAL, COMP COMPRESSION 

SPRING, FLAT 

APERTURE SIGHT 

SCREW, REAR SIGHT WINDAGE 



END OF FIGURE 



SECTION 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




(1) 


(2) 


(3) 


(4) 


:tem 


SMR 




PART 


NO 


CODE 


CAGEC 


NUMBER 



Figure C-9. Forward Assist Assembly M 16 Al, 9349086. 

(5) (6) 

DESCRIPTION AND USABLE ON CODES (UOC) QTY 

GROUP 030201 FIG C-9 
FORWARD ASSIST ASSEMBLY 
M16A1 (9349086) 



1 PAFZZ 19200 9349085 

2 PAFZZ 13629 95113 

3 PAFZZ 19200 8448542 

4 PAFZZ 19204 8448544 

5 PAFZZ 19204 8448543 



FORWARD ASSIST PAWL 



PLUNGER ASSEMBLY . 

UOC: 194 

PIN, SPRING 

UOC:194 

SPRING, HELICAL, COMP COMPRESSION 

UOC:194 

DETENT, PAWL 

UOC:194 

PAWL, FORWARD ASSIST 

UOC: 194 

END OF FIGURE 



C-9-1 



SECTION 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




NOTE 
Early model M16 rifles did not 
have a recess in wliicli to install 
item no (1 1) spring, helical com- 
pression or item no. (1 2) detent, 
takedown pin. Pivot pin (1 5) NSN 
1005-00-992-6671, must be used 
on this model. 



Figure C-10. Lower Receiver and Extension Assembly M16, 8448604 andM16Al, 8448578. 



SECTION II 



TM9-1005-249-23SP 

AIR FORCE TO llW-3-5-5-24 

COAST GUARD CMDTINST M8370.9 



(1) 


(2) 


(3) 


(4) 


ITEM 


SMR 




PART 


NO 


CODE 


CAGEC 


NUMBER 



(5) 



DESCRIPTION AND USABLE ON CODES (UOC) 



(6) 



QTY 



GROUP 04 FIG C-10 
LOWER RECEIVER AND EXTENSION 
ASSEMBLY H16 (8448604) AND 
H16A1 (8448578) 



1 


PAOZZ 


19204 


8448629 


2 


PAOZZ 


19200 


8448615 


3 


AFFFF 


19204 


8448610 


4 


PAFZZ 


19200 


8448595 


5 


PAFZZ 


19204 


8448630 


6 


PAFZZ 


19204 


8448633 


7 


PAFZZ 


19204 


8448634 


8 


PAFZZ 


19200 


8448628 


9 


PAFZZ 


96906 


MS16562-119 


10 


PAFZZ 


19204 


8448638 


11 


PAOZZ 


19204 


8448586 


12 


PAOZZ 


19204 


8448585 


13 


PAFZZ 


19204 


8448637 


14 


PAFZZ 


19204 


8448636 


15 


PAOZZ 


19204 


8448621 


15 


PAOZZ 


13629 


95601 


16 


PAFZZ 


19200 


8448635 


17 


AFFFF 


19204 


8448591 


18 


PAOZZ 


88044 


AN501D416-1 


19 


PAOZZ 


96906 


MS 35335-61 


20 


PAOZZ 


19200 


9349127 


21 


PAOZZ 


19204 


8448516 


22 


PAOZZ 


19204 


8448631 


23 


PAFZZ 


19204 


8448609 


24 


PAFZZ 


19204 


8448599 


25 


PAOZZ 


19204 


8448584 


26 


PROZZ 


19200 


9349129 


27 


PAOOO 


19200 


9349119 


28 


PAOZZ 


19200 


9349128 


29 


XAFFA 


19204 


8448605 



SPRING, HELICAL, COMPRESSION 

BUFFER ASSEMBLY 

HAMMER ASSY (SEE FIG.C-12 FOR 

BREAKDOWN) 

SEAR AUTOMATIC ASSEMBLY 

LEVER, SELECTOR 

SPRING, HELICAL, COMPRESSION 

PLUNGER, BOLT CATCH 

CATCH, BOLT 

PIN, SPRING STEEL 

CATCH, MAGAZINE 

SPRING, HELICAL, COMPRESSION 

PIN, STRAIGHT, HEADLE PIN 

SPRING, HELICAL, COMPRESSION 

BUTTON, MAGAZINE CAT CATCH 

PIN, PIVOT 

PIN, PIVOT (SEE NOTE ON FIG C-10) 

UOC;755 

DISCONNECTOR 

TRIGGER ASSY (SEE FIG.C-13 FOR 

BREAKDOWN) 

SCREW, MACHINE, FILLI 

WASHER, LOCK 

GRIP, RIFLE PLASTIC, BLACK 

SPRING, HELICAL, COMPRESSION 

DETENT, SAFETY 

PIN, GROOVED, HEADLES TRIGGER 

PIN, GROOVED, HEADLES 

PIN, TAKEDOWN 

SPACER, STEPPED 

BUTTSTOCK ASSEMBLY 

SCREW, SELF-LOCKING 

LOWER RECEIVER, AND EXTENSION 

SUBASSEMBLY, M16 (SEE FIG C-14 FOR 

BREAKDOWN) 

UOC;755 

LOWER RECEIVER AND EXTENSION 

SUBASSEMBLY, M16A1 (SEE FIG C-14 

FOR BREAKDOWN) 

UOC: 194 



END OF FIGURE 



SECTION II 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




Figure C-ll. Buttstock Assembly 9349119 



(1) 


(2) 


(3) 


(4) 


ITEM 


SMR 




PART 


NO 


CODE 


CAGEC 


NUMBER 



1 PAOZZ 19200 9381380 

2 PAOZZ 19200 9349130 

3 PAOZZ 19200 8448653 

4 XAOZZ 19200 9349121 

5 PAOZZ 19204 8448652 

6 PAOZZ 19204 8448655 

7 PAOZZ 19200 9349120 



(5) (6) 

DESCRIPTION AND USABLE ON CODES (UOC) QTY 

GROUP 0401 FIG C-ll 
BUTTSTOCK ASSEMBLY 9349119 

DOOR ASSEMBLY, THUMB 1 

PLATE, BUTT, SHOULDER 1 

HINGE, ACCESS DOOR ACCESS DOOR BUTT 1 

PLATE 

BUTTSTOCK 1 

SWIVEL, SLING, SMALL 1 

PIN, STRAIGHT, HEADLESS 1 

SCREW, SELF-LOCKING 1 

END OF FIGURE 



C-11-1 



SECTION II 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




(1) (2) (3) 

ITEM SMR 
NO CODE CAGEC 



1 PAFZZ 19204 8448611 

2 PAFZZ 19200 8448612 



Figure C-12. Hammer Assembly 8448610. 

(4) (5) 

PART 
NUMBER DESCRIPTION AND USABLE ON CODES 



GROUP 0402 FIG C-12 
HAMMER ASSEMBLY 8448610 

SPRING, HELICAL, TORSION 

HAfflER, FIRING, SMALL 



(UOC 



(6) 

QTY 



. . 1 
. . 1 



END OF FIGURE 



C-12-1 



SECTION 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 
COAST GUARD CMDTINST M8370.9 





Figure C- 13. Trigger Assembly 8448591. 



(1) 


(2) 


(3) 


(4) 


ITEM 


SMR 




PART 


NO 


CODE 


CAGEC 


NUMBER 



1 PAFZZ 19200 8448594 

2 PAFZZ 19204 8448593 

3 PAFZZ 19204 8448592 



(5) (6) 

DESCRIPTION AND USABLE ON CODES (UOC) QTY 

GROUP 0403 FIG C-13 
TRIGGER ASSEMBLY 8448591 

SPRING, HELICAL, COMP COMPRESSION .... 1 
SPRING, HELICAL , TORSION 1 

TRIGGER 1 

END OF FIGURE 



C-13-1 



SECTION 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 




Figure C-14. Lower Receiver and Extension Subassembly M16, 8448605 and M16A1, 8448579. 



(5) 



(1) 

TEM 


(2) 

SMR 


(3) 


PART 




NO 


CODE 


CAGEC 


NUMBER 


DESCRIPTION 



(6) 



AND USABLE ON CODES (UOC) QTY 



GROUP 0404 FIG C-14 
LOWER RECEIVER AND EXTENSION 
SUBASSEMBLY M16 (8448605) AND 
M16A1 (8448579) 



1 PAFZZ 19200 8448581 

2 PAFZZ 19204 8448582 

3 PAFZZ 19200 8448583 

4 PAFZZ 19204 8448587 

5 PAFZZ 96906 MS16562-35 

6 XAFDD 19204 8448606 



6 XAFDD 19204 8448580 



HOLDER, SPRING RECEIVER 1 

PIN, SHOULDER, HEADLE 1 

SPRING, HELICAL, COMP COMPRESSION . . . . 1 

GUARD, TRIGGER 1 

PIN, SPRING 1 

RECEIVER, LOWER NOTE: SERIAL 1 

NUMBER CONTROL M16 

UOC: 755 

RECEIVER, LOWER NOTE: SERIAL 1 

NUMBER CONTROL M16A1 

UOC:194 



END OF FIGURE 



C-14-1 



SECTION 



TM 9-1005-249-23&P 

AIR FORCE TO 11W-3-5-5-24 

COAST GUARD CMDTINST M8370.9 



Section 



SPECIAL TOOLS LIST 




7799792 M^e <* MfSAf 



-th 






BARm rROSION {cm>MF 

PLATTD BORE) -8448196 M7S * MfSA) 



^ 




Figure C-15. Special tools. 



SECTION III 




COAST I 


(1) (2) 


(3) 


(4) 


ITEM SMR 




PART 


NO CODE 


CAGEC 


NUMBER 



TM9-1005-249-23SP 
AIR FORCE TO llW-3-5-5-24 
COAST GUARD CMDTINST M8370.9 
(5) 



DESCRIPTION AND USABLE ON CODES (UOC) 



(6) 
QTY 



GROUP 9500 FIG C-15 
SPECIAL TOOLS 



ADFFA 



19204 



8426685 



1 


PAFZZ 


19205 


7799809 


2 


PAFZZ 


19204 


8448201 


3 


PAFZZ 


19200 


12620101 


4 


PAFZZ 


19204 


8448496 


5 


PAFZZ 


19204 


8448677 


6 


PAFZZ 


19204 


8448202 


7 


PAFZZ 


19204 


12006359 


8 


PAFZZ 


19204 


7799734 


9 


PAFZZ 


19204 


7799735 


10 


PAFZZ 


19204 


11010032 


11 


PAFZZ 


19204 


11010033 


12 


PAFZZ 


19205 


7799792 


13 


PAFZZ 


19204 


12006472 



TOOL AND GAGE SET DS/GS SUPPORT 
MAINTENANCE FOR 5.56MM RIFLE M16 
RIFLE SERIES BOI : 2 PER SUPPORTING 
DSU/GSU 

. .CASE, CARRYING, GAGE PART OF KIT P/ 
N 8426685 (M16 ONLY) 

..REFLECTOR TOOL, CHAMBER, PART OF 
KIT P/N 8426685 

. .GAGE, PLUG, PLAIN PART OF KIT P/N 

8426685 

. .GAGE, BARREL, EROSION PART OF KIT 
P/N 8426685 (CHROME BARREL) 

. .GAGE, MUZZLE EROSION PART OF KIT 
P/N 8426685 (NON-CHROME BARREL) 

. .GAGE, STRAIGHTNESS PART OF KIT P/ 
N 8426685 

..CASE, BORE GAGE PART OF KIT P/N 

8426685 

. .GAGE, HEADSPACE PART OF KIT P/N 

8426685 

. .GAGE, FIRING PIN PROTRUSION PART 
OF KIT P/N 8426685 

. .FIXTURE, BARREL REMOVAL PART OF 
KIT P/N 8426685 

. .WRENCH, COMBINATION PART OF KIT P/ 
N 8426685 

. .GAGE, BARREL EROSION PART OF KIT 
P/N 8426685 (NON-CHROME BARREL) 

.. GAGE, PLUG, TAPER CYLINDER PART 
KIT P/N 8426685 



END OF FIGURE 



C-15-1 



TM9-1005-249-23&P 
AIR FORCE TO llW-3-5-5-24 
COAST GUARD CMDTINST M8370.9 
SECTION IV 

CROSS-REFERENCE INDEXES 

NATIONAL STOCK NUMBER INDEX 



STOCK NUMBER 



STOCK NUMBER 



5315-00-017-9537 
3040-00-017-9539 
1005-00-017-9540 
5360-00-017-9541 
1005-00-017-9543 
1005-00-017-9545 
1005-00-017-9547 
1005-00-017-9548 
1005-00-017-9551 
5315-00-017-9552 
1005-00-056-2201 
5360-00-056-2246 
1005-00-056-2247 
5315-00-058-6044 
5365-00-064-2652 
5220-00-070-7814 
6695-00-070-7815 
4933-00-070-9151 
5120-00-070-9152 
1005-00-087-8998 

1005-00-152-3441 
5220-00-155-4925 
5220-00-221-9391 
5365-00-252-6853 
5315-00-282-3642 
1005-00-403-0964 
5340-00-463-3892 
5315-00-463-3894 
5360-00-523-8084 
5310-00-527-3634 
5315-00-597-5086 
1005-00-738-6213 
1005-00-760-3768 
4933-00-800-7508 
5315-00-812-3312 
5315-00-814-3530 
1005-00-921-5004 
1005-00-933-8089 
1005-00-937-3078 
1005-00-978-1022 
5315-00-978-1023 
5360-00-978-1025 
1005-00-978-1025 
5360-00-978-1027 
5355-00-978-1029 
1005-00-978-1030 
5360-00-978-1032 
4710-00-978-1038 
5315-00-979-3930 



C-10 


15 


C-9 


5 


C-9 


4 


C-8 


7 


C-7 


4 


C-1 


2 


C-2 


1 


C-10 


8 


C-12 


2 


C-9 


2 


C-10 


10 


C-10 


5 


c-10 


7 


C-6 


7 


C-8 


2 


C-15 


8 


C-15 


9 


C-15 


10 


C-15 


11 


C-6 


8 


C-6 


9 


C-6 


4 


C-15 


5 


C-15 


5 


C-6 


10 


C-8 


10 


C-11 


5 


C-11 


3 


c-11 


5 


c-9 


3 


C-10 


19 


C-3 


4 


C-4 


3 


C-3 


8 


C-15 


2 


C-10 


9 


C-14 


5 


C-1 


4 


C-6 


5 


C-10 


2 


C-8 


4 


C-8 


3 


C-8 


5 


C-8 


14 


C-8 


13 


C-8 


9 


C-8 


11 


C-8 


12 


C-6 


2 


C-7 


2 



5360-00-979-3931 
5360-00-992-5548 
1005-00-992-5549 
5315-00-992-5550 
5315-00-992-5551 
5360-00-992-5552 
5315-00-992-5553 
5315-00-992-5554 
5360-00-992-5555 
5360-00-992-5565 
5340-00-992-5566 
1005-00-992-5567 
1005-00-992-5571 
1005-00-992-7280 
5315-00-992-7283 
5305-00-992-7284 
1005-00-992-7285 
1005-00-992-7287 
1005-00-992-7288 
1005-00-992-7290 
1005-00-992-7291 
5360-00-992-7292 

5315-00-992-7294 
5340-00-992-7297 
1005-00-992-7299 
5360-00-992-7301 
1005-00-992-7302 
1005-00-992-7307 
5360-00-992-7308 
5315-00-992-7309 
5360-00-992-7311 
5360-00-999-0404 
5340-00-999-0405 
1005-00-999-0406 
1005-00-999-1509 
5220-01-014-8183 
5315-01-027-4759 
4933-01-035-5507 
5220-01-043-9473 
5320-01-063-7535 
5220-01-075-5004 
1005-01-134-3525 
1005-01-134-3529 
1005-01-135-4973 
1005-01-144-1468 
5305-01-144-1494 
1005-01-146-7585 
5365-01-146-7592 
5305-01-147-8585 



C-7 


3 


C-12 


1 


C-10 


4 


C-10 


24 


C-14 


2 


C-14 


3 


C-10 


25 


C-10 


12 


C-10 


11 


C-10 


1 


C-10 


5 


C-10 


22 


C-10 


15 


C-6 


6 


C-4 


2 


C-4 


1 


C-2 


4 


C-3 


1 


C-3 


7 


C-3 


3 


C-3 


6 


C-3 


5 


C-10 


21 


C-2 


3 


C-14 


1 


C-14 


4 


C-10 


13 


C-10 


14 


C-13 


3 


C-13 


2 


C-10 


23 


C-13 


1 


C-5 


2 


C-5 


3 


C-10 


16 


C-2 


2 


C-15 


4 


C-8 


6 


C-15 


7 


C-15 


13 


C-7 


5 


C-15 


3 


C-7 


1 


C-6 


3 


C-10 


27 


C-9 


1 


C-11 


7 


C-11 


2 


C-10 


26 


C-10 


28 



TM9-1005-24 9-2 3£P 
AIR FORCE TO llW-3-5-5-24 
COAST GUARD CMDTINST M8370.9 
SECTION IV 



CROSS-REFERENCE INDEXES 



NATIONAL STOCK NUMBER INDEX 



STOCK NUMBER 



STOCK NUMBER 



1005-01-148-4805 
1005-01-216-4510 
1005-01-228-8504 
1005-01-248-5858 
5305-01-268-1191 



C-10 

C-1 

C-11 

C-8 



SECTION IV 



CROSS-REFERENCE INDEXES 



TM9-1005-249-23SP 

AIR FORCE TO llW-3-5-5-24 

COAST GUARD CMDTINST M8370 



PART NUMBER INDEX 



CAGEC 


PART NUMBER 


88044 


AN501D416-18 


96906 


MS 16562-106 


96906 


MS16562-119 


96906 


MS16562-121 


96906 


MS 16562-35 


96906 


MS 16562-96 


96906 


MS 16562-98 


96906 


MS16626-1137 


96906 


MS16632-1012 


96906 


MS 35335-51 


19204 


11010032 


19204 


11010033 


19204 


12006359 


19204 


12006472 


19200 


12576280 


19200 


12620101 


19204 


12624561 


19204 


7799734 


19204 


7799735 


19205 


7799792 


19205 


7799809 


19204 


8426685 


19204 


8448201 


19204 


8448202 


19204 


8448496 


19204 


8448501 


19204 


8448502 


19204 


8448503 


19204 


8448504 


19204 


8448505 


19200 


8448506 


19200 


8448507 


19204 


8448508 


19200 


8448509 


19204 


8448510 


19204 


8448511 


19204 


8448512 


19204 


8448513 


19204 


8448515 


19204 


8448516 


19204 


8448517 


19204 


8448518 


19200 


8448519 


19204 


8448520 


13629 


8448521-2 


19204 


8448522 


19204 


8448523 


19204 


8448525 


19204 


8448532 


19204 


8448533 



STOCK NUMBER 



5305-01- 
5315-00- 
5315-00- 
5315-01- 
5315-00- 
5315-00- 
5315-00- 
5365-00- 
5365-00- 
5310-00- 
4933-00- 
5120-00- 
4933-01- 
5220-01- 
1005-01- 
5220-01- 
1005-01- 
5220-00- 
6695-00- 



268-1191 
058-6044 
812-3312 
027-4759 
814-3530 
282-3642 
597-5086 
252-6853 
064-2652 
527-3634 
070-9151 
070-9152 
035-5607 
043-9473 
248-5858 
075-5004 
216-4510 
070-7814 
070-7815 



4933-00-800-7508 
5220-00-221-9391 

5220-01-014-8183 

5315-00-992-7294 

1005-00-017-9547 
1005-00-999-1509 

5315-00-992-7283 

1005-00-738-6213 
5305-00-992-7284 

1005-00-992-7285 

1005-00-992-7287 
1005-00-992-7288 
1005-00-992-7290 
1005-00-992-7291 

5360-00-992-7292 

1005-00-017-9546 

5340-00-999-0405 
5360-00-999-0404 



1005-00-978-1022 
5360-00-978-1025 
5315-00-978-1023 



C-10 


18 


C-6 


7 


C-10 


9 


C-8 


6 


C-14 


5 


C-8 


10 


C-3 


4 


C-6 


10 


C-8 


2 


C-10 


19 


C-15 


10 


C-15 


11 


C-15 


7 


C-15 


13 


C-8 


1 


C-15 


3 


C-1 


5 


C-15 


8 


C-15 


9 


C-15 


12 


C-15 


1 


C-15 


1 


C-15 


2 


C-15 


6 


C-15 


4 


C-1 


1 


C-2 


3 


C-2 


1 


C-2 


2 


C-2 


5 


C-4 


2 


C-4 


3 


C-4 


1 


C-2 


4 


C-3 


2 


C-3 


1 


C-3 


7 


C-3 


3 


C-3 


6 


C-3 


5 


C-10 


21 


C-1 


2 


C-5 


4 


C-5 


3 


C-5 


2 


C-5 


1 


C-1 


3 


C-6 


1 


C-8 


4 


C-8 


5 


C-8 


3 



SECTION IV 



CROSS-REFERENCE INDEXES 



TM9-1005-249-23SP 

AIR FORCE TO llW-3-5-5-24 

COAST GUARD CMDTINST M8370 





PART NUMBER INDEX 


CAGEC 


PART NUMBER 


19204 


8448534 


19200 


8448535 


19200 


8448536 


19200 


8448537 


19200 


8448538 


19204 


8448539 


19200 


8448540 


19200 


8448542 


19204 


8448543 


19204 


8448544 


19200 


8448567 


19204 


8448571 


19204 


8448573 


19204 


8448574 


19204 


8448576 


19204 


8448577 


19204 


8448578 


19204 


8448579 


19204 


8448580 


19200 


8448581 


19204 


8448582 


19200 


8448583 


19204 


8448584 


19204 


8448585 


19204 


8448586 


19204 


8448587 


19204 


8448591 


19204 


8448592 


19204 


8448593 


19200 


8448594 


19200 


8448595 


19204 


8448599 


19204 


8448601 


19204 


8448602 


19204 


8448603 


19204 


8448604 


19204 


8448605 


19204 


8448605 


19204 


8448609 


19204 


8448610 


19204 


8448611 


19200 


8448612 


19200 


8448615 


19204 


8448621 


19200 


8448628 


19204 


8448629 


19204 


8448630 


19204 


8448631 


19204 


8448633 


19204 


8448634 


19200 


8448635 



STOCK NUMBER 



5355- 


-00- 


-978- 


-1029 


5350- 


-00- 


-978- 


-1027 


1005- 


-00- 


-978- 


-1030 


5350- 


-00- 


-978- 


-1032 


1005- 


-00- 


-978- 


-1026 


5350- 


-00- 


-017- 


-9541 


5350- 


-00- 


-523- 


-8084 


3040- 


-00- 


-017- 


-9539 


1005- 


-00- 


-017- 


-9540 


4710- 


-00- 


-978- 


-1038 


1005- 


-00- 


-017- 


-9543 


5315- 


-00- 


-979- 


-3930 


5350- 


-00- 


-979- 


-3931 


1005- 


-00- 


-933- 


-8089 


1005- 


-00- 


-992- 


-7280 



5340-00-992-7297 
5315-00-992-5651 
5350-00-992-5652 
5315-00-992-5653 
5315-00-992-5554 
5350-00-992-5555 
1005-00-992-7299 

1005-00-992-7307 
5350-00-992-7308 
5360-00-992-7311 
1005-00-992-5549 
5315-00-992-5550 



5315-00-992-7309 

5350-00-992-5548 

1005-00-017-9551 
1005-00-937-3078 
5315-00-017-9537 
1005-00-017-9548 
5350-00-992-5565 
5340-00-992-5566 
1005-00-992-5567 
5350-00-055-2246 
1005-00-055-2247 
1005-00-999-0406 



C-8 


15 


C-8 


9 


C-8 


13 


C-8 


11 


C-8 


12 


C-8 


14 


C-8 


7 


C-9 


3 


C-9 


5 


C-9 


4 


C-6 


2 


C-7 


4 


C-7 


2 


C-7 


3 


C-6 


5 


C-6 


6 


C-1 


5 


C-10 


29 


C-14 


5 


C-14 


1 


C-14 


2 


C-14 


3 


C-10 


25 


C-10 


12 


C-10 


11 


C-14 


4 


C-10 


17 


C-13 


3 


C-13 


2 


C-13 


1 


C-10 


4 


C-10 


24 


C-1 


3 


C-6 


1 


C-8 


1 


C-1 


5 


C-10 


29 


C-14 


5 


C-10 


23 


C-10 


3 


C-12 


1 


C-12 


2 


C-10 


2 


C-10 


15 


C-10 


8 


C-10 


1 


C-10 


5 


C-10 


22 


C-10 


5 


C-10 


7 


C-10 


16 



SECTION IV 



CROSS-REFERENCE INDEXES 



TM9-1005-249-23SP 

AIR FORCE TO llW-3-5-5-24 

COAST GUARD CMDTINST M8370 





PART NUMBER INDEX 


CAGEC 


PART NUMBER 


19204 


8448636 


19204 


8448637 


19204 


8448638 


19204 


8448652 


19200 


8448653 


19204 


8448655 


19204 


8448663 


19200 


8448670 


19204 


8448677 


19204 


8448697 


19204 


8448712 


19200 


8448755 


19200 


9349056 


19200 


9349059 


19200 


9349085 


19204 


9349086 


19200 


9349119 


19200 


9349120 


19200 


9349121 


19200 


9349127 


19200 


9349128 


19200 


9349129 


19200 


9349130 


19200 


9381380 


13629 


95113 


13629 


95601 



STOCK NUMBER 

1005-00-992-7302 
5360-00-992-7301 
1005-00-056-2201 

1005-00-403-0964 
5340-00-463-3892 
5315-00-463-3894 
1005-00-152-3441 
1005-00-921-5004 
5220-00-155-4925 
5320-01-063-7635 
1005-00-087-8998 

1005-00-760-3768 
1005-01-134-3625 
1005-01-134-3629 
1005-01-144-1468 

1005-01-135-4973 
5305-01-144-1494 

1005-01-148-4805 
5305-01-147-8585 
5355-01-146-7692 
1005-01-146-7685 
1005-01-228-8504 
5315-00-017-9552 
1005-00-992-6671 



C-10 


14 


C-10 


13 


c-10 


10 


C-11 


5 


C-11 


3 


c-11 


6 


C-6 


4 


C-1 


4 


C-15 


5 


C-7 


5 


C-6 


8 


C-6 


9 


C-3 


8 


C-7 


1 


C-6 


3 


C-9 


1 


C-8 


8 


C-10 


27 


C-11 


7 


C-11 


4 


C-10 


20 


C-10 


28 


C-10 


26 


C-11 


2 


c-11 


1 


c-9 


2 


C-10 


15 



TM9-1005-249-23&P 



COAST GUARD CMDTINST M8370.9 
AIR FORCE TO llW-3-5-5-24 



SECTION IV 



CROSS-REFERENCE INDEXES 
FIGURE AND ITEM NUMBER INDEX 



STOCK NUMBER 



PART NUMBER 



C-1 


1 


C-1 


2 


c-1 


3 


c-1 


3 


c-1 


4 


c-1 


5 


c-1 


6 


c-1 


6 


C-2 


1 


C-2 


2 


C-2 


3 


C-2 


4 


C-2 


5 


C-3 


1 


C-3 


2 


C-3 


3 


C-3 


4 


C-3 


5 


C-3 


6 


C-3 


7 


C-3 


8 


C-4 


1 


C-4 


2 


C-4 


3 


C-5 


1 


C-5 


2 


C-5 


3 


C-5 


4 


C-6 


1 


C-6 


1 


C-6 


2 


C-6 


3 


C-6 


4 


C-6 


5 


C-6 


6 


C-6 


7 


C-6 


8 


C-6 


9 


C-6 


10 


C-7 


1 


C-7 


2 


C-7 


3 


C-7 


4 


C-7 


5 


C-8 


1 


C-8 


1 


C-8 


2 


C-8 


3 


C-8 


4 


C-8 


5 


C-8 


6 



1005-00-017-9545 



1005-00-921-5004 
1005-01-216-4510 



1005-00-017-9547 
1005-00-999-1509 

5315-00-992-7294 
1005-00-992-7285 

1005-00-992-7287 

1005-00-992-7290 
5315-00-597-5085 
5360-00-992-7292 
1005-00-992-7291 
1005-00-992-7288 
1005-00-760-3768 
5305-00-992-7284 
5315-00-992-7283 
1005-00-738-6213 

5360-00-999-0404 
5340-00-999-0405 



4710- 


-00- 


-978- 


-1038 


1005- 


-01- 


-134- 


-3629 


1005- 


-00- 


-152- 


-3441 


1005- 


-00- 


-933- 


-8089 


1005- 


-00- 


-992- 


-7280 


5315- 


-00- 


-058- 


-6044 


1005- 


-00- 


-087- 


-8998 


1005- 


-00- 


-087- 


-8998 


5365- 


-00- 


-252- 


-6853 


1005- 


-01- 


-134- 


-3625 


5315- 


-00- 


-979- 


-3930 


5360- 


-00- 


-979- 


-3931 


1005- 


-00- 


-017- 


-9543 


5320- 


-01- 


-063- 


-7635 



1005-01-248-5858 
5365-00-064-2652 
5315-00-978-1023 
1005-00-978-1022 
5360-00-978-1025 
5315-01-027-4759 



19204 
19204 
19204 
19204 
19200 
19204 
19204 
19204 
19204 
19204 
19204 
19200 
19204 
19204 
19204 
19204 
96906 
19204 
19204 
19204 
19200 
19204 
19200 
19200 
13629 
19204 
19200 
19204 
19204 
19204 
19200 
19200 
19204 
19204 
19204 
96906 
19204 
19204 
96906 
19200 
19204 
19204 
19204 
19204 
19204 
19200 
96906 
19204 
19204 
19204 
96906 



8448501 


8448517 


8448522 


8448601 


8448670 


12624561 


8448578 


8448604 


8448503 


8448504 


8448502 


8448509 


8448505 


8448511 


8448510 


8448513 


MS 16562-98 


8448516 


8448515 


8448512 


8448755 


8448508 


8448506 


8448507 


8448521-2 


8448520 


8448519 


8448518 


8448523 


8448602 


8448567 


9349059 


8448663 


8448576 


8448577 


MS 16562-106 


8448712 


8448712 


MS16626-1137 


9349056 


8448573 


8448574 


8448571 


8448697 


8448603 


12576280 


MS16632-1012 


8448533 


8448525 


8448532 


MS 16562-121 



TM9-1005-249-23&P 



COAST GUARD CMDTINST M8370.9 
AIR FORCE TO llW-3-5-5-24 



SECTION IV 



CROSS-REFERENCE INDEXES 
FIGURE AND ITEM NUMBER INDEX 



STOCK NUMBER 



PART NUMBER 



C-8 


7 


C-8 


8 


C-8 


9 


C-8 


10 


C-8 


11 


C-8 


12 


C-8 


13 


C-8 


14 


C-8 


15 


C-9 


1 


C-9 


2 


C-9 


3 


C-9 


4 


C-9 


5 


C-10 


1 


C-10 


2 


c-10 


3 


c-10 


4 


c-10 


5 


c-10 


6 


c-10 


7 


c-10 


8 


c-10 


9 


c-10 


10 


c-10 


11 


c-10 


12 


c-10 


13 


c-10 


14 


c-10 


15 


c-10 


15 


c-10 


16 


c-10 


17 


c-10 


18 


c-10 


19 


c-10 


20 


c-10 


21 


c-10 


22 


c-10 


23 


c-10 


24 


c-10 


25 


c-10 


26 


c-10 


27 


c-10 


28 


c-10 


29 


c-10 


29 


C-11 


1 


C-11 


2 


c-11 


3 


c-11 


4 


c-11 


5 


c-11 


6 



5360-00-017-9541 

5355-00-978-1029 
5315-00-282-3642 
1005-00-978-1030 
5360-00-978-1032 
5360-00-978-1027 
1005-00-978-1026 

1005-01-144-1468 
5315-00-017-9552 
5360-00-523-8084 
1005-00-017-9540 
3040-00-017-9539 
5360-00-992-6665 
1005-00-937-3078 



1005- 


-00- 


-992- 


-6649 


5340- 


-00- 


-992- 


-6666 


5360- 


-00- 


-056- 


-2246 


1005- 


-00- 


-056- 


-2247 


1005- 


-00- 


-017- 


-9548 


5315- 


-00- 


-812- 


-3312 


1005- 


-00- 


-056- 


-2201 


5360- 


-00- 


-992- 


-6655 


5315- 


-00- 


-992- 


-6654 


5360- 


-00- 


-992- 


-7301 


1005- 


-00- 


-992- 


-7302 


1005- 


-00- 


-992- 


-6671 


5315- 


-00- 


-017- 


-9537 


1005- 


-00- 


-999- 


-0406 



5305-01-268-1191 
5310-00-527-3634 
1005-01-148-4805 
5360-00-992-7292 
1005-00-992-6667 
5315-00-992-7309 
5315-00-992-6650 
5315-00-992-6653 
5365-01-146-7692 
1005-01-135-4973 
5305-01-147-8585 



1005-01-228-8504 
1005-01-146-7685 
5340-00-463-3892 

1005-00-403-0964 
5315-00-463-3894 



19200 
19204 
19200 
96906 
19200 
19200 
19200 
19204 
19204 
19200 
13629 
19200 
19204 
19204 
19204 
19200 
19204 
19200 
19204 
19204 
19204 
19200 
96906 
19204 
19204 
19204 
19204 
19204 
13629 
19204 
19200 
19204 
88044 
96906 
19200 
19204 
19204 
19204 
19204 
19204 
19200 
19200 
19200 
19204 
19204 
19200 
19200 
19200 
19200 
19204 
19204 



8448540 


9349086 


8448535 


MS16562-96 


8448537 


8448538 


8448536 


8448539 


8448534 


9349085 


95113 


8448542 


8448544 


8448543 


8448629 


8448615 


8448610 


8448595 


8448630 


8448633 


8448634 


8448628 


MS16562-119 


8448638 


8448586 


8448585 


8448637 


8448636 


95601 


8448621 


8448635 


8448591 


AN501D416-1 


MS35335-61 


9349127 


8448516 


8448631 


8448609 


8448599 


8448584 


9349129 


9349119 


9349128 


8448579 


8448605 


9381380 


9349130 


8448653 


9349121 


8448652 


8448655 



TM9-1005-249-23&P 



COAST GUARD CMDTINST M8370.9 
AIR FORCE TO llW-3-5-5-24 



SECTION IV 



CROSS-REFERENCE INDEXES 
FIGURE AND ITEM NUMBER INDEX 



C-11 


7 


C-12 


1 


C-12 


2 


C-13 


1 


C-13 


2 


C-13 


3 


C-14 


1 


C-14 


2 


C-14 


3 


C-14 


4 


C-14 


5 


C-14 


6 


C-14 


6 


C-15 


1 


C-15 


1 


C-15 


2 


C-15 


3 


C-15 


4 


C-15 


5 


C-15 


6 


C-15 


7 


C-15 


8 


C-15 


9 


C-15 


10 


C-15 


11 


C-15 


12 


C-15 


13 



STOCK NUMBER 

5305-01-144-1494 
5360-00-992-6648 
1005-00-017-9551 
5360-00-992-7311 
5360-00-992-7308 
1005-00-992-7307 
5340-00-992-7297 
5315-00-992-6651 
5360-00-992-6652 
1005-00-992-7299 
5315-00-814-3530 



4933-00-800-7508 
5220-01-075-5004 
5220-01-014-8183 
5220-00-155-4925 
5220-00-221-9391 
4933-01-035-5607 
5220-00-070-7814 
6695-00-070-7815 
4933-00-070-9151 
5120-00-070-9152 

5220-01-043-9473 



CAGEC 


19200 


19204 


19200 


19200 


19204 


19204 


19200 


19204 


19200 


19204 


96906 


19204 


19204 


19204 


19205 


19204 


19200 


19204 


19204 


19204 


19204 


19204 


19204 


19204 


19204 


19205 


19204 



PART NUMBER 



9349120 


8448611 


8448612 


8448594 


8448593 


8448592 


8448581 


8448582 


8448583 


8448587 


MS 16562-35 


8448580 


8448606 


8426685 


7799809 


8448201 


12620101 


8448496 


8448677 


8448202 


12006359 


7799734 


7799735 


11010032 


11010033 


7799792 


12006472 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

APPENDIX D 

EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST 

Section 1. INTRODUCTION 

D-1 . SCOPE. This appendix lists expendable/durable supplies and materials you will need to operate and maintain the 
5.56mm Rifle M16 and M16A1. This listing is for informational purposes only and is not authority to requisition the 
listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V, 
Repair Parts, and Heraldic Items), or CTA 8-100, Army Medical Department Expendable/Durable Items. 

D-2. EXPLANATION OF COLUMNS. 

a. Column (1) — ^Item Number. This number is assigned to the entry in the listing and is referenced in the narrative 
instructions to identify the material (e.g., "Use cloth, abrasive, crocus, item 12, bpp DP') 

b. Column (2)-Level. This column identifies the lowest level of maintenance that requires the listed item. 

C - Operator/Crew 

O - Unit Maintenance 

F - Direct Support Maintenance 

H - General Support Maintenance 

c. Column (3) — National Stock Number. This is the National stock number assigned to the item; use it to request or 
requisition the item. 

d. Column (4)-Description. indicates the Federal item name and, if required, a description to identify the item. The 
last line for each item indicates the Federal Supply Code for Manufacturer (FSCM) in parentheses followed by the part 
number. 

e. Column (5) — Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance function. 
This measure is expressed by a two-character alphabetical abbreviation (e.g., ea, in., pr). If the unit of measure differs 
from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements. 



Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST 



(1) 

Item 
Number 


(2) 

Level 


(3) 

National 

Stock 

Number 


(4) 

Description 


(5) 
U/M 


1 


F 


8040-00-944-7292 


ADHESIVE KIT: 

(81 348) MMM-A-1754 


KT 


2 


C 


1005-00-242-5687 


BOTTLE ASSEMBLY, CYLINDRICAL 
( 19204) 8448444 


EA 


3 





8020-00-244-0153 


BRUSH, ARTIST'S: metal furrule, flat 
chisel edge 7/1 6 w, 1 1/8, exposed 
bristle (81 348) H-B-241 


EA 


4 


c 


1005-00-903-1296 


BRUSH, CLEANING, SMALL ARMS; bore 
(1 9204) 11686340 


EA 


5 


c 


1005-00-999-1435 


BRUSH, CLEANING, SMALL ARMS: 
chamber (1 9204) 8432358 


EA 


6 


c 


1005-00-494-6602 


BRUSH, CLEANING, SMALL ARMS: tooth 
(1 9204) 8448462 


EA 



I 



D-1 



ARMY TM9-1005-249-23SP 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370 



(1) 



(2) 



(3) 



(4) 



(5) 



Item 

Number 



National 

Stock 

Number 



Description 



U/M 



7920-00-205-2401 



BRUSH, CLEANING, TOOLS AND PARTS 
(96906) MS 16746-29 



6850-00-965-2332 



CARBON REMOVING COMPOUND 
(81348) P-C-111 



9150-01-102-1473 
9150-01-079-6124 
9150-01-054-6453 
9150-01-053-6688 



CLEANER, LUBRICANT AND PRESERV- 
ATIVE: (27412) 
CLP 1/2 OZ BOTTLE 
CLP-4 4 OZ BOTTLE 
CLP-5 PT BOTTLE 
CLP-7 GAL BOTTLE 



9920-00-292-9946 



CLEANER, TOBACCO PIPE: 
(92849) DILLS (32 PER PK) 



6850-00-224-6656 
6850-00-224-6657 
6850-00-224-6663 



CLEANING COMPOUND, RIFLE BORE: 
SMALL ARMS BORE CLEANING SOLUTION 
(RBC) 

(81349) HIL-C-372 
2-OZ (59.15-ML) BOTTLE 
8-OZ (236.59-ML) CAN 
1-GAL (3.79-L) CAN 



5350-00-221-0872 



CLOTH, ABRASIVE 
(58536) A-A-1206 



!010-00-181-7859 



COATING COMPOUND, FLUORESCENT: 
PAINT FOR BLANK FIRING ATTACHMENT 
(81349) HIL-P-21563 
1 PT CAN 



6810-00-244-0290 

6810-00-616-9188 



DICHLOROHETHANE, TECHNICAL 
(81349) HIL-D-6998 
5 GAL PAIL 
600 LB DRUM 



6850-00-281-1985 



DRY CLEANING SOLVENT 
(58536) A-A-711 
1 GAL CAN 



8415-00-823-7457 
SIZE 11 

8415-00-823-7456 
SIZE 10 

8415-00-823-7455 
SIZE 9 



GLOVES, CHEMICAL AND OIL 
PROTECTIVE 
(81348) ZZ-G-381 



ARMY TM9-1005-249-23SP 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



(1) 



(2) (3) 



(4) 



(5) 



National 
Item Stock 

Number Level Number 



9150-00-754-2595 



Description 



GREASE, MOLYBDENUM DISULFIDE 
(81349) MIL-G-21164 



U/M 
LB 



1005-01-113-0321 



HANDLE SECTION, CLEANING ROD, 
SMALL ARMS : 
(19204) 8436776 



1150-01-260-2534 



LUBRICANT, SOLID FILM: 
(81349) MIL-L23398 
16 OZ SPRAY CAN 



9150-00-292-9689 



LUBRICATING OIL, WEAPONS: (LAW) 
(81349) MIL-L-14107 
1 QT (0.95-L) CAN 



QT 



9150-00-935-6597 
9150-00-889-3522 

9150-00-687-4241 
9150-00-753-4686 



LUBRICATING OIL, WEAPONS: (LSA), 
SEMIFLUID (81349) MIL-L-46000 

2-OZ {59.15-ML) PLASTIC BTL OZ 

4-OZ {118.30-ML) PLASTIC BTL OZ 

1-QT {0.95-L) CAN QT 

1-GAL {3.79-L) CAN GL 



4940-00-795-3595 



PAN, WASH: 
(94453) 1211 



6850-00-826-0981 



PENETRANT KIT: KT 
(81349) MIL-L-25135 



7920-00-205-1711 



RAG, WIPING: 
(81348) DDD-R-30 
50 LB BDL 



1005-00-050-6357 



ROD SECTION, CLEANING, 
SMALL ARMS : 
(19204) 8436775 (3 REQUIRED) 



8030-00-670-8553 



SEALING COMPOUND; 
(93648) DEVCONF 



1005-00-937-2250 



SWAB HOLDER SECTION, CLEANING 
ROD, SMALL ARMS : 
(19204) 11586327 



1005-00-912-424i 



SWAB, SMALL ARMS 
(19204) 11686408 



8115-00-190-5002 



BOX, SHIPPING, FIBERBOARD 
(81348) PPP-B-636 



:115-00-023-0301 



BOX, SHIPPING, FLAPS 
(81348) PPP-B-601 



ARMY TM9-1005-249-23SP 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



(1) 



(2) (3) 



(4) 



(5) 



National 
Item Stock 

Number Level Number 



8135-00-855-5969 



Description 



CUSHIONING MATERIAL 
(81348) PPP-C-843 



U/M 
EA 



7510-00-297-6655 



TAPE, PRESSURE SENSITIVE 
(81348) PPP-T-76 



;135-00-810-4075 



BARRIER MATERIAL. 
GREASE-PROOFED, WATERPROOFED 
FLEXIBLE 
(81349) MIL-B-121 



;105-00-264-5523 



ENVELOPE PACKAGING 
(81349) MIL-B-117 



:135-00-938-1565 



FIBERBOARD, CORRUGATED 
(81348) PPP-F-320 



;115-00-616-9151 



BOX, SHIPPING 
(81348) PPP-B-640 



;115-00-685-5171 



BOX, SHIPPING 
(81348) PPP-B-621 



:135-01-019-1691 



SHEET, POLYETHYLENE 
(84744) PE88-80-2 



ARMY TM 9-1005-249-23&P 

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COAST GUARD COMDTINST M8370.9 



APPENDIX E 
ILLUSTRATED LIST OF MANUFACTURED ITEMS 



INTRODUCTION. 



a. This appendix includes complete instructions for making items authorized to be manufactured or fabricated at unit 
or direct support leveL 

b. A part number in alphanumeric order is provided for cross-referencing the part number of the item to be manufac- 
tured to the figure which covers fabrication criteria. 

c. All bulk materials needed for manufacture of an item are listed in a tabular list on the illustration. 
d. | Figures E-1| and E-3 may be fabricated by Direct Support Maintenance. 

e. l Figure E-21 may be fabricated by Unit Maintenance. 

INDEX 

Item Figure 

Number 



Front sight post and low light level front sight post removing and installation tool 

Pivot pin removing tool 

Key tool 

Front sight detent depressor 



M 



Pivot pin installation tool I..E-5 




720 



MATERIAL BLOCK 

FSCM 81346 ASTM A686 METAL BAR 

STEEL, GRADE C, GLASS W2-09 

HOT ROLLED, ROUND, 0.375 INCH NOMINAL 

DIAMETER, 3 FOOT NOMINAL LONG 

NSN 9510-00-640-4407 OR EQUIVALENT 



NOTE 

Teeth must be hand filed to fit front 
sight post. 



MATERIAL: MILD STEEL 

NOTE: ALL DIMENSIONS SHOWN ARE IN INCHES AND KNURLING IS OPTIONAL IF DESIRED. 

Figure E-1. Front sight post and low light level front sight post removing and installation tool. 



I 



E-1 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 




NOTE: 1. FABRICATE FROM 1/16 IN, SOCKET HEAD SCREW KEY NSN 5120-00-198-5398 OR EQUIVALENT 
2. ALL DIMENSIONS ARE IN INCHES. 

AR 922734 

Figure E-2. Pivot pin removing tool. 



0.292 A _ 
DIA ~f 



2-1/2 



ALL DIMENSIONS SHOWN ARE IN INCHES 



-^ 



0.123 R 



_r 



0.175 TO 0.180 
DIA 



U— 0. 



U0.750J * 



868-^ 



NOTE: ALL DIMENSIONS SHOWN ARE IN INCHES 

MATERIAL BLOCK 

FSCM 81346 ASTM A686 METAL BAR 

STEEL, GRADE C, CLASS W209 

HOT ROLLED, ROUND 0.375 INCH NOMINAL 

DIAMETER, 3 FOOT NOMINAL LONG 

NSN 9510-00-640-4407 OR EQUIVALENT 



Figure E-3. Key tool. 



AR 922842 



E-2 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 



±.02 



.080 DIA STK WIRE 




.625±.C20R 



FABRICATE FROM .08 IN. MUSIC WIRE OR EQUIVALENT. 

FINISH: NO. 5. 3.1.2 OR 5.3.2.2 OF MIL-STD-17 

NOTE: ALL DIMENSIONS ARE IN INCHES. 

Figure E-4. Front sight detent depressor. 



SECTION A-A 



B .005 



.096 



.000 
THRU 






2.50 + .0! 



1 1/2 MIN 



005 MAX BOW FOR 

LENGTH |— A — 

1/8 



TOTAL [^ ^ /j 
+ .04 DIA J / ' ^- A 



L .01 RMAX OR 

.01 X 46 MAX CHAMFER 



1.50 ±,06 




25 + .05R 



245 ^'^'^^ DIA STOCK 
-.004 



FABRICATE FROM .249 IN. STEEL A1S1 1095 OR EQUIVALENT. 

HARDEN AND TEMPER TO RC-57-61 FOR LENGTH A- 
FINISH 5.3.1.2 OR 5.3.2.2 OR MIL.-STD-171 . 

NOTE: ALL DIMENSIONS ARE IN INCHES. 

Figure E-5. Pivot pin installation tool. 



E-3 {E-4 blank) 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

APPENDIX F 
TORQUE LIMITS 
INTRODUCTION. 

a. This appendix includes a standard torque table of the most commonly torque screws, bolts, and nuts. 

b. These torque values may be used when torque values are not specified. 

c. The torque table values are given in inch-pounds. If a torque wrench is calibrated in foot-pounds, you need to 
divide the listed number by 12 to obtain the desired torque. 

STANDARD TORQUE TABLE (INCH-POUNDS) 
Torque Values In Inch-Pounds for Tightening Nuts 



Bolt, Stud, or On standard bolt, studs, and screws having a 
Screw Size tensile strength of 125,000 to 140,000 psi. 



On bolts, studs, and 
screws having a ten- 
sile strength of 
140,000 to 160,000 

psi. 



On high-strength bolts, 
studs, and screws hav- 
ing a tensile strength of 
160,000 psi and over. 





Sheer type nuts 


Tension type nuts and 


Any nut, except 


Any nut, except shear 




(AM320, AN364, 


threaded machine parts 


shear type 


type 




or equivalent) 


(AN310, AN365, or 
equivalent) 






8-32 


7-9 


12-15 


14-17 


15-18 


8-36 


7-9 


12-15 


14-17 


15-18 


10-24 


12-15 


20-25 


23-30 


25-35 


1 /4-20 


25-30 


40-50 


45-49 


50-68 


1/4-28 


30-40 


50-70 


60-80 


70-90 


5/16-18 


48-55 


90-90 


85-117 


90-114 


5/16-24 


60-85 


100-140 


120-172 


140-203 


3/8-1 6 


95-110 


160-186 


173-217 


185-248 


3/8-24 


95-110 


160-190 


175-271 


190-351 


7/16-14 


140-155 


235-255 


245-342 


255-428 


7/16-20 


270-300 


450-500 


475-628 


500-756 


1/2-13 


240-290 


400-480 


440-636 


480-792 


1/2-20 


290-410 


480-690 


585-840 


690-990 


9/16-12 


300-420 


500-700 


600-845 


700-990 


9/16-18 


480-600 


800-1,000 


900-1,220 


1,000-1,440 



F-1 (F-2 blank) 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

ALPHABETICAL INDEX 
Subject Page 



Annual Inspection and Gaging, M16 and M16A1 I 3-721 

Assemblies 



Bolt Assembly r^l^ 



Bolt Carrier Assembly I 2-24 



Buttstock Assembly .12-52 

Charging Handle Assembly I 2-33 



[ins 

[331] 



Forward Assist Assembly i 3-471 

Hammer Assembly 13-601 

Key and Bolt Carrier Assembly I 3-191 

Lower Receiver and Extension Assembly I 2-451 I 3-501 

Lower Receiver and Extension Subassembly 13-621 

Trigger Assembly J 3-611 

Upper Receiver and Barrel Assembly 12-351 13-231 

Upper Receiver Assembly I 3-401 

Auxiliary Equipment 

Bayonet-Knife M7 [4^ 

Bayonet-Knife Scabbard M8A1 or M10 FTTI 

Blank Firing Attachment M15A2 14-121 

Lock Plate r474] 

Low Light Level Front Sight I 4-21 

Rifle Bipod M3 14-101 

Top Sling Adapter 1.4-71 

B 

Bayonet-Knife M7 [E] 

Bayonet-Knife Scabbard !I/I8A1 or M10 [±^\ 

Blank Firing Attachment II/I15A2 14-121 

Cleaning 14-1 31 

inspection 14-1 31 

installation 14-121 

Removal 14-121 

Repainting 14-131 

Replacement I.4.-.1 31 

Bolt Assembly I3.t59[ 13-151 

Cleaning r23Ql FsTTal 

Disassembly FT^ggi F^^TSI 

inspection/Repair 12-301 13-151 

Lubrication fl^ITl [3^18] 

Reassembly flTsTl [3^181 

Bolt Carrier Assembly TT^T^ nTTTI 

Cleaning 12-251 

Disassembly [2^24] [FTTI 

Inspection ^^ ^^ 

Reassembly r2727l [3^14] 

Repair [2^25] [3^14] 

Test FS^TSI 

Buttstock Assembly L2-52I 

Disassembly 12-.:? 2 1 

inspection L2.-53I 

Reassembly J 2-54 1 

i3 



Repair =........ 2-5 



Index 1 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 



Subject Page 



Characteristics, Capabilities, Features, and Equipment 1 1-21 

Charging Handle Assembly I 2-33| 

Disassembly I.2-33| 

Inspection/Repair 12-341 

Lubrication L2-34I 

Reassembly 12-341 

Checks and Services, Preventive Maintenance 12-31 

Cleaning 

Blank Firing Attachment M15A2 14-131 

Bolt Assembly VT^im nTTg] 

Bolt Carrier Assembly 12-251 

Common Tools and Equipment I 2-11 1 3-11 

D 

Data Equipment 1 1-31 

Decontamination of Rifles and Arms Rooms J 2-21 1 

Decontamination of Sights Activated with Tritium (H3) I 2-211 , 1 3-91 

Destruction of Army Materiel to Prevent Enemy Use 1 1-11 

Differences between Models 1 1-31 

Disassembly 

Bolt Assembly TT^^m FTTSI 

Bolt Carrier Assembly rT:^m FTTn 

Buttstock Assembly 12-521 

Forward Assist Assembly I 3-481 

Hammer Assembly 13-601 

Key and Bolt Carrier Assembly 13-191 

Low Light Level Sight 14-21 

Lower Receiver and Extension Assembly 12-451 1 3-501 

Lower Receiver and Extension Subassembly I 3-621 

Trigger Assembly I.3-.61 1 

Upper Receiver and Barrel Assembly 12-351 1 3-231 

Upper Receiver Assembly 13-401 

E 

Equipment Characteristics, Capabilities, and Features J 1-21 

Equipment Description and Data J 1-21 

Equipment improvement Recommendations (EIR), Reporting 11-11 

Expendable/Durable Supplies and Materials List J D-l| 

F 

Features, Equipment Characteristics, Capabilities and 1 1-21 

Final Inspection, Ml 6 and M16A1 Rifle 13-701 

Gaging 13-731 

Inspection I 3-701 

Firing Pin Protrusion Gaging 13-711 

Forward Assist Assembly 13-471 

Disassembly 13-481 

Inspection 13-481 

Repair 13-491 

Reassembly 13-491 



Index 2 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

Subject Page 



Gaging (See applicable module) 

H 

Hammer Assembly 1.3-601 

Disassembly 13-601 

inspection/Repair I 3-611 

Reassembly 1.376.1 1 

How to Use This Manual | iii | 

I 

Illustrated List of Manufactured items I E-ll 

Inspection 

Blank Firing Attachment M15A2 14-131 

Bolt Carrier Assembly I 2-25L 13-121 

Buttstock Assembly 12-531 

Forward Assist Assembly I 3-481 

Hammer Assembly 1 3-611 

Low Light Level Sight 14-131 

Lower Receiver and Extension Assembly I 2-47L I 3-531 

Lower Receiver and Extension Subassembly I 3-641 

Trigger Assembly 13-621 

Upper Receiver and Barrel Assembly I 2-36L 13-261 

Inspection/Repair 

Bolt Assembly f^;^?!?! rTTSl 

Key and Bolt Carrier Assembly I 3-2QI 

inspection, Final M16 and M16A1 13-701 

Inspection, Preembarkation of Materiel in Units Alerted for Overseas Movement I 3-731 

Installation 

Blank Firing Attachment M15A2 14-121 

Lock Plate 1 4.- 4 J 

Low Light Level Front Sight 14-31 

Major Components of M16/M16A1 Rifle 13-101 

Rifle Biped M3 L4.-.10I 

Top Sling Adapter 1.4-71 

K 

Key and Bolt Carrier Assembly 13-191 

Disassembly 1 3-. 1.91 

Repair 13-201 

Reassembly 13-201 

L 

Location and Description of Major Components L1-:2I 

Lock Plate 

installation 14:41 

Removal 14-51 



Index 3 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

Subject Page 

L (Cont) 

Low Light Level Front Sight 

Disassembly J .47.21 

Inspection J Ar.SI 

Installation nt75l 

Reassembly 1. 4-. 3 1 

Wrapping and Packaging 1 .4 -.31 

Lower Receiver and Extension Assembly 

Disassembly |.2r.45| 13-501 

inspection 1 .27.4 7 1 1 3-531 

Reassembly IT491 1 3-581 

Repair I.2r.48l 13-551 

Test nr;?Bi 

Low Receiver and Extension Subassembly 

Disassembly |.3.-jB3I 

Inspection 13-641 

Reassembly 13-671 

Repair/Modify 13-651 

Test I.3.-:66I 

Lubrication 

Bolt Assembly 1^311 mm 

Bolt Carrier Assembly I 2-271 

Lubrication General I 2-221 

M 

Maintenance Allocation Chart | B-1 

Maintenance Forms, Records and Reports 1 1-11 

Major Components of M16 and M16A1 Rifle 12-231 15-101 

Disassembly [gT^^ r^TTOI 

Reassembly 1 2-551 [3^681 

Stowage 12-561 

Test rsTeg] 

Manufactured Items, illustrated List of I E-ll 

Materials List, Expendable/Durable Supplies and |. D-1 | 

M7 Bayonet-Knife TTTT 

M8A1 or Ml 0, Bayonet-Knife Scabbard ITT1 

M16 and M16A1 Rifle Annual inspection and Gaging 13-721 

M16 and M16A1 Rifle Final inspection 13-701 

Mechanical Zero Procedures I 2-431 1 3-461 



Official Nomenclature, Names and Designations | I-l| 

Operation, Principles of [M] 



Index 4 



ARMY TM 9-1005-249-23&P 

AIR FORCE TO 11W3-5-5-24 

COAST GUARD COMDTINST M8370.9 

Subject Page 



Parts, Repair, Special Tools, TMDE, and Support Equipment J 2-11 

Preembarkation Inspection of Materiel in Units Alerted for Overseas Movement J 3-731 

Preparation for Storage or Shipment 11-114-131 

Preventive Maintenance Clieclts and Services 12-31 

Principles of Operation OH 

Purpose of II/I16/IW16A1 Rifle Pm 



Reassembly 

Bolt Assembly C^l^TI FTTgl 

Bolt Carrier Assembly FITtI \TT4\ 

Buttstock Assembly 12-541 

Forward Assist Assembly I 3-491 

Hammer Assembly 13-611 

Key and Boll Carrier Assembly 13-201 

Low Light Level Front Sight IT^ 

Lower Receiver and Extension Assembly I 2-49L I 3-581 

Lower Receiver and Extension Subassembly I 3-671 

Trigger Assembly 13-621 

Upper Receiver and Barrel Assembly 12-361 13-301 

Upper Receiver Assembly 13-451 

References 

Removal 



A.l 



Blank Firing Attachment 14-121 

Lock Plate FT^ 

Rifle Biped MS |.4r11| 

Top Sling Adapter f?^ 

Repair 

Bolt Assembly riTSOl 13^151 

Buttstock Assembly 12-541 

Forward Assist Assembly 13-491 

Lower Receiver and Extension Assembly 12-481 1 3-551 

Lower Receiver and Extension Subassembly I 3-651 

Upper Receiver Assembly I 3-421 

Repair Parts and Special Tools List |C-1 | 

Repair Parts [.CtItII 

Special Tools JCr15-1 | 

Replacement 

Blank Firing Attachment II/I15A2 1 4 - 1 31 

Reporting Equipment Improvement Recommendations (EIR) 11-11 

Restamping Serial Numbers I 3-661 

Rifle Bipod M3 

Instaliation 14-101 

Removal |.4.t11| 

Rifles and Arms Rooms, Decontamination of 12-211 



Index 5 



ARMY TM 9-1005-249-23&P 
AIR FORCE TO 11W3-5-5-24 
COAST GUARD COMDTINST M8370.9 

Subject Page 



Serial Numbers J 3-66 1 

Service Upon Receipt of Materiel I. 2-113-11 

Sights Activated with Tritium (H3), Decontamination of I 2-21I . I3-9I 

Stowage 

Major Components of M16 and M16A1 Rifle FS^Sgl 



Test 

Bolt Carrier Assembly [T 



Lower Receiver and Extension Assembly \J 

Lower Receiver and Extension Subassembly [T 

Major Components of M16 and M16A1 Rifle [I 

Upper Receiver and Barrel Assembly E 

Top Sling Adapter E 



m 



TB 



J] 



561 



351 



3 



Installation 14-71 

Removal \T1\ 

Torque Limits I F-1 I 

Trigger Assembly I 3-611 

Disassembly 13-611 

Inspection I -3^621 

Reassembly 13-621 

Troubleshooting 12-121 1 3-21 



Upper Receiver and Barrel Assembly | 2-35] [^-221 

Disassembly |2-35j| 3-23] 

Inspection FTJe] TTm 

Repair FTm VTm 

Reassembly r^TI \T1U\ 

Test IT^ 

Upper Receiver Assembly 

Disassembly I J-4U| 

Inspection/Repair I j-42| 

Reassembly I 3-45| 

W 

Wrapping and Packaging I . 4H3,4-T3| 



Zero Procedures, Mechanical L 2-43U 3-461 



Index 6 



By Order of the Secretary of the Army: 



GORDON R. SULLIVAN 

General, United States Army 

cftief of Staff 
Official: 



PATRICIA P. HICKERSON 

Brigadier General, United States Army 
The Adjutant General 

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 



W.T. LELAND, Rear Admiral 

Chief, Office Law 

Enforcement and Defense Operations 

U.S. Coast Guard 



DISTRIBUTION : 

To be distributed in accordance with DA Form 12-40E, (Block 0136), Unit, 
Direct and General Support Maintenance requirements for TM 9-1005-249-23&P . 



"U.S. Government Printing Office: 1995-388-421/40073 



RECOMMENDED CHANGES TO PUBLICATIONS AND 
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DATE 



TOi (Forwmrd to proprntmnt ai ptAllemtion er larm) (tncludm ZIP Codm) 

Commander 

U. S. Army AMCCOM 

ATTN: AMSMC-MAS 

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PART t . ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS 



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Rifle, Ml 6 ^TiH MI^AI 



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1-13 



Change zip code from 61201 to 61299. 
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Change zip code from 61201 to 61299. 
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19 June 1991 



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Gommander 

U.S. Army AMCCOM 

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DATE 



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Rifle, M16 and M16A1 



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19 June 1991 



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TOl (ForwmrtI direcr to mddietttt liaftl in pubUcmiioi}} 

Commander 

U.S. Army AMCCOM 

ATTN: AMSMC-MAS 

Rock Island, IL 61299-6000 


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DATE 


PART II - REPAIR PARTS AMD SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS | 


PUBLICATION NUMBER 

TM 9-1005-249-23&P 


DATE 

19 June 1991 


TITLE 

Rifle, M 


16 and M16A1 


PAGE 

NO. 


COLM 
NO. 


LINE 
NO. 


FEDERAL STOCK 
NUMBER 


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NO. 


FIGURE 
NO. 


ITEM 
NO. 


TOTAL NO. 

OF MAJOR 

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Use Part U (reverfta) for Repair Parts jnd 
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TH 9-1005-249-23&P 



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DATE 

19 June 1991 



TITLE 



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NO. 



FEDERAL STOCK 

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DA PUBLICATIOM/FORM NUMDER 

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USAPDC-S LABEL4-26S (01 CX^TOBER 93) PREVIOUS EDITION MAY BE USED TILL. EXHAUSTED 



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068570- 000