For the bolt, once you get it out, check that the ejector is springy. Ensure the extractor moves. It might or might not have crane o-ring under the extractor, but even if it does not, I doubt this would give you the symptoms you are seeing. If it does have one though, it wouldn't hurt to install one (you have to drive the extractor pin out to do this).
Ensure the gas seal rings do not have holes lined up. Even if they are, the bolt will usually still work OK, but good practise to space them apart.
Now blow on the hole in the gas key to verify it is not obstructed.
If all those things ckeck out, re-assemble the bolt carrier group as it's likely OK.
Before shooting, lube the living crap out of the sides of the gas key, the cam pin and the bearing rails on the bolt carrier. In my experience, many (most?) Ar15 failures are related to insufficient lubrication.
Use a good runny gun oil like Hoppes, Remoil, CLP, etc.
The idea of the gas ring gaps having to be lined up is total BS and unicorn-like in it's mythicalness. I have fired AR's and full-auto C7/C8's with 1 (one) gas ring and none of them ever failed to work.
My 14.5" mid-length has never seen oil at all only Motomaster Wheel Bearing and Axle grease and now has somewhere north of 12K thru it without a single stoppage so the idea of "only good runny oil" has been proven fallacious and by others far more qualified than I.
As to the OP's problem, I would suggest getting your hands on a good AR15 manual and getting familiar with the workings of the rifle before you go suggesting that you're thinking of tearing down the BCG and removing the gas key. The system isn't difficult to work on but it seems that everyone with an AR15 instantaneously becomes an armourer. Next thing you know we'll be seeing posts about how Brand X is a piece of crap and doesn't work properly but most (if any) will never mention that they buggered with it since day 1...
blake
Blake,
A properly tuned and broken-in AR will run with only one gas ring and any lube you want to use.
I merely want the OP to try the obvious things according to good practise. If he gets his gun working well, he can try non-issue lubes and other interesting things.
The OP can spend all the time inthe world screwing with the bolt and the gas system and other things but it is all a waste of time cause the problem is in the chamber. Nothing in the bolt, buffer, recoil spring or gas system would cause the extractor to rip the case rim off. That is the result of the case sticking in the chamber.
Tuned and broken-in nothing - I've done it with new out of the box rifles and no issue. It's still bad data. There is much of it on this site from folks who don't know what they don't know (from the Four Levels of Competence).
I think everybody who buys an AR should have to read the manual before they start going all "Lego-maniac" on their new toy, if even so they at least learn proper terminology.
I'm not sure exactly what you mean by "non-issue lubes and other interesting things", maybe I'm reading too much into it...
The OP can spend all the time inthe world screwing with the bolt and the gas system and other things but it is all a waste of time cause the problem is in the chamber. Nothing in the bolt, buffer, recoil spring or gas system would cause the extractor to rip the case rim off. That is the result of the case sticking in the chamber.
I mean that the M16 manual of arms doesn't have grease anywhere in it. It specifies Break-free CLP and for trouble-shooting that is what he should be using. (or something very like it)
Your "luck" with out of the box rifles is irrelevant. The fact is his rifle does not work and he needs to test it in optimal configuration.



























