So I had the exact same issue with a PSA ar when I first got it...round was all the way in battery but I couldnt get it to come back out...probably a bad idea but I opened up the upper off the lower re cocked the hammer and fired the case out...never had an issue ever again.
I did notice that I had a wear mark on the upper where the cam pin rotates over, and Ive seen a lot of PSA uppers so that. My guess is the cam pin was resting against the inside of the upper and caused the issue till it made just enough clearance to fit.
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COTEP# CBOB0669
DW Specialist 9mm, Para GI Expert, Springfield Range Officer 9mm, Sig P229R Dark Elite, Sig P320, STI Edge 9mm
Ruger Wiley Clapp GP100, Springfield XDs 4.0
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