Check this while you are at it
I think that the answer to your problem may be very simple. My ar-15 had exactly the same problem that you describe. The problem may be the j-spring in the hammer pivot hole. It is not listed seperately anywhere that I have found.
This spring is only maybe 1/2 inch long, J shaped and should protrude into the hammer pivot hole. supposedly this spring is rivited in the hammer and should not fall out during dissasembly.
Mine did and caused quite a headache.
I pulled one out of another hammer, installed it and problem solved.
Try a different hammer if nothing else. Let me know if this works.
Later.
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