I have a MK 2 this is about 25 years old I have owned it over 15 years. It hasn't had more than a brick of shells thru it. I have always had a issue with dissassembly. I have only had it apart once. The problem is in the main spring housing. The spring tab will pop out to release the housing but the housing only moves a little bit then stops. What appears to be happening is the roll pin, #5 in the diagram, has backed out and is catching on the frame. Has anybody ever encountered this? Is there a way to get is apart without damaging anything?
Depends on how far over the bolt stop pin, pivot pin has drifted. I've only had this situation happen twice in the 44 years I've been involved with gun repair. On one occasion I could see the end of the pin and that allowed me to get a shim between the grip frame and the mainspring housing and push the pin to the right until I could free the mainspring housing and pull it out. The other situation involved a much worse scenario. The left end of the bolt stop pin drifted over and past the slight shoulder in the grip frame, not offering the left end to push either right, or left. I then took a hack-saw blade and ground it as thin as I could get it, dunking the blade in water to keep its temper regularly. Of course, the tooth-set was removed and the blade was pretty thin, but I was able to get the blade through the tiny gap between the mainspring housing and the grip frame to saw the bolt stop pivot pin almost through, until the thin metal that was left broke the pin in two. That exercise took quite a while to get done for a 1/8-inch diameter pin. After that fiasco, whenever I have a Ruger Mark pistol on my bench and it gets taken apart, the mainspring housing bolt latch and bolt stop pin, pivot pins get staked on the very edge of each side of each pin three times, 120-degrees apart. Punching a dimple in the center of those pins, as done at Ruger, is just not sufficient enough to prevent those pins from drifting, and it seems they always go to the left. When I dimple the edges of those pins, it rolls metal over and into the gap between the pin and housing, in three places, 120-degrees apart, or as close to that as you can get, it always seems to keep those pins from drifting. I've never seen a "rivet" that helps hold the weld-laminated mainspring housing together, drift out, though.