To All Concerned,
This "Marlin Jam" thing takes some years to develop depending on your shooting {lever'n} ability. I shoot it hard and fast; therefore, faster wear'n........ Just be aware of the "catchity" on the close of the lever and know: "Ye MUST" do something in the next few months depending if ye shoot every weekend or not....
The Marlin 1894 lever gun is EASY to take apart... LOL... It's put'n it back together..... not toooo difficult if you pay'd attention and learn'd how the pieces work on dis-assembly. The Lever - Slide/Bolt - Ejector Spring {if I'm NOT using the correct "terms" please forgive me as a "Smitty" I'm not} are obvious and a no-brain er.... I remove-clean-lube {I used Tetra Teflon grease at slide 'n lever area} for every cleaning.
At this time you can see the sharp edge that Longshot Lil' pointed out on the lever, but the "slot" that is created after awhile is on the "Lifter / Carrier" part still inside and this is where it gets a bit more difficult as the hammer-trigger/sear-springs are involved with the lifter as I remembers it.
According to some of the "Fixes" out there rounding off that sharpness on the lever takes away (as small as it is - sometimes this is a huge amount) some "lift" of the "carrier" and the rounds fall short of the barrel breach and now the jam is at the bullet nose and the bottom edge of the barrel.....
The "Fix" continues by what is removed from the lever is now added to the lifter/carrier with a "harder" metal shim that is JB Weld'd or some other adhesive in place as I believe that solder-braze [heat] would ruin the "cast" part. This is considered a "permanent" fix 'till the metal shim goes away for some reason and now you have a jam with NO warning.......
.....
I respect the talent of Gunsmiths to over-come and adapt; however, all this has to come apart to be fixed anyway.... the part IS available and why ruin the lever too. ( If I where a talented Ol' Cuss I'd put a roller bear'n at the sharp lever point in the correct spot for lifter operation and timing).... In my "box of stuff" I have a spare NEW lifter-carrier to cut down order / backorder time.
CHECK This OUT>>>>Marauder's Marlin Jam Fix>>>>>>
<<<<<With Pictures<<<<<:
http://marauder.homestead.com/files/Marlin94Fix.html