I carried one of these for the better half of three years during my tenure as a blood sucking security contractor in Baghdad. I know I abused the absolute piss out of mine. I "drove" it like I stole it. I was the primary firearms instructor and range officer for the US Embassy Security Force in Baghdad. I was also the Chief Armorer for about the last year that I was there.
This is all fancy talk for "I got to basically shoot as much as I want."
So I did.
If you keep an M-4 wet it will work quite well. I shot Colts, F/N's, and Bushmasters. (M-4s, M-16A4's, and XM-15's)
What breaks?:
1. Gas tubes are a consumable when going full throttle.
2. I put close to 15K rounds through my barrel before I swapped it out.
3. Replace extractor springs and use the high durometer rubber thingy on M-4's as the gas tube length and port ID makes the gun less forgiving on brass and the timing is more "abrupt". You need the extra pressure to prevent the claw from slipping over the case rim. Especially when going full throttle.
4. Hammer springs and buffer springs both get replaced at the same time. Do this and you won't have issues. Don't and all bets are off.
5. Gas rings are a consumable when going full throttle. Best way I've found to test to see if they are good or not is to extend the bolt carrier assy fully forward (out of battery) and carefully set the assembly bolt face down on a table. The rings should support the weight of the assembly. Now make a fist and rap the table with a single firm strike using the meaty part of your hand. The bolt assy should start to rotate into battery. It should not however go fully into battery. If it does the rings are junk and should be replaced. It should be a little lazy when collapsing also. This "ultra scientific" method is basically checking the ring's diametric tension on the bore of the bolt carrier. Clean your bolt assy prior to this test as loads of gunk/funk/carbon skew the truth.
the sustained rate of fire for these buggers is 12-15 rounds per minute. They are not crew serve guns. It's an assault rifle with the capability of fully automatic fire- to be used in short controlled bursts. Do otherwise and you exceed the design parameters of the weapon system and you'll likely experience some sort of stoppage or component failure.
Ammunition.
In the "Wild West" days (04-07) of Iraq ammunition was literally what ever could be obtained. Especially for crummy scum sucking contractors because we weren't bound to Geneva convention technicalities. (that and nobody really liked us anyway cause we got paid $200K/year or more to do the job of a "Lance Criminal".
So, long story short I've shot everything from top shelf Black Hills match stuff with 80 grain Hornady A-max bullets to "Billy Bob's wholesale Wolf ammo outlet".
If you shoot Wolf you better have a sloppy wet gun and it better not be hot out. (Meaning Baghdad hot) The steel cased stuff is coated/treated with some kind of fugly lacquer finish and it begins to cook itself to chambers. Chambers get smaller and smaller until you start tearing the rims off cases and guns don't work no more. (I'm now a 4th order ninja with a cleaning rod because of this)
My thoughts:
The M-4 is a great weapon system so long as the 1st echelon preventive maintenance is performed with diligence. I don't mean scrubbing bores like its a bench gun a Division CG inspection. I mean keep the thing wet and when it loads up with gunk, just scrub most of it off and then get it wet again. Do this and it'll run like a raped ape for a very long time. It's a close tolerance firearm, so it will only put up with crap for so long. The AK will certainly put up with more crap but it also shoots like total crap. You can be reasonably confident of hitting your target with an M-4. With an AK I'm not yet convinced. (The ergonomics of the AK-47 are just horrible IMO. I shot the snot out of them as well since we had a guard cadre in Northern Kurdistan who were all local nationals.)
Regarding catastrophic failures resulting in rifles sending their operators to the Corpsman.
I was first introduced to the M-16 weapon system as a Marine in 1990. I was a PMI for four years of my enlistment and I've been a service rifle shooter since that same time. Add all the other things I've done and yada yada. In the 19 years of fiddling with these things I've seen a gun blow up three times. Once on active duty during Division Matches and twice in Iraq by another security company. All three incidents resulted in the upper receiver splitting along the forging line and ejaculating the magazine and it's contents out the bottom the rifle. In all events the shooter had to go change his panties and get a band aid. It does happen but in all cases the rifles had been very, very, very heavily used with literally tens of thousands of rounds sent down range. I'd have to question the level 2 repair/maintenance records and the LTI's performed in each event.
Nothing lasts forever. . .
Peeves:
Ever shoot/handle one of these things in a middle eastern summer? It's brutal and your face will glow in the dark at the end of the day. They get so damn miserably hot that it's almost unbearable. I got really good at sweating in Baghdad and most of it was due to a rifle that I could cook food with. This is/was regardless of whether I was shooting it or not. If it's in the sun more than ten minutes your going to be a burn victim, count on it. Now add the fact that it's a direct gas operating system and you begin to really appreciate things like pistons and cylinders up under a hand guard away from your face.
Hope this answered the OP's questions.
Cheers,
Chad
Chad Dixon
LongRifles, Inc.