I compared it with my other 2 ARs and looks the same
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Hard to tell from just a single pic, but it looks like the gas key is hitting the flare on the tube a bit harder on one side than the other.
Is it an abnormal amount? I cannot say from here. (Nothing is perfect)
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Was thinking the same.
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Tracking this thread. Great discussion and pics throughout. This is what forums are all about. 
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The gas key on the bcg is canted, all the bcg is out of specs.
Watch my previous picturesā¦
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I need to send the whole upper back to PSA.
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Yes. I saw earlier.
I could not see the issue with your Gas Key in your original pictures, but after seeing the pic of the canted key, and your earlier description of your FTF, this wear-mark is unsurprising.
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Thatās awesome youāll be able to send in the complete upper, instead of the whole rifle. That way youāll have it shipped directly back to you, instead of your FFL and paying any fees. Iām betting once PSA receives it, it wonāt take them to long to diagnose it, and fix whatever issues they need to do. Please keep a record of this process and continue to keep us all in the loop and update here. Iāve never had to ship anything back to PSA, but Iām confident they will do a fine job. But Iād love to see from an actual customer, the timeline on all this.
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Most of my guns are PSA, this is going to be the first time I send something back, still waiting for their reply.
I will keep you guys posted on the process.
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Hell yeah, and it BEGINS! lol
Iām guessing this may vary from state to state. Here in Ohio the manufacturer returns the warrantied firearm directly to the owner without going through a FFL.
The same even holds true for NFA items. I shipped a defective can (buggered threads from the factory) to Sig and they returned it directly to me.
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same here, spook
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Same here also. Sent a rifle from Nebraska to Missouri for a warranty repair and they sent it back directly to me.
No transfer is happening because its already yours.
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Alright, I got an email from PSA, they will send me a return label so I can send the upper for inspection and repair or replace!
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Outstanding! Hopefully you have a big enough shipping box, and some filler material ie: packing peanuts or some bags of air, something along those lines. Thanks for the update man, I definitely appreciate it and your effort to post here and keep everyone updated timewise and the outcome altogether. I still say itās got to be a gassing issue. I know the BCG is out of spec, thatās definitely not helping anything. But I canāt see it being the only thing thatās causing all these issues? Who knows, maybe Iām totally wrong here. Stay tuned for the exciting conclusion to this story! LoL
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Alright guys, I got my PSA return label after letting them know what is going on with the upper.
Iām telling you, I donāt understand who complains about PSA customer service, they got to me fast and after sending them some pictures and description of the malfunction everything went good to go!
I truly believe in PSA, Iām sure they are going to find whatās wrong and will fix and or repair it and send it back as soon as they can.
Iāll keep you guys updatedā¦
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People who are just angry/like to throw tantrums.
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Customer service used to be nearly impossible to get ahold of. It was extremely frustrating. Once you got to them, they were very helpful. You just couldnāt get to anyone. For weeks. I havenāt had to contact them recently, though, so I wonāt say itās the same today. Glad you had a good experience out of the gate. The complaints were certainly warranted in the past.
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have you taken the bolt apart and inspected it?, is the gun dry? what is the ejection pattern? should be 3-430