I have read somewhere before more than once that Benchmade's warranty is void if you take your knife apart. Why do they sell the tool kit then??
The tool kit is a separate product. There is no stated intention that you should use your tool kit to disassemble your knife. The AFCK can be cleaned quite adequately with spray-in solvent cleaners.
And now you know why BM doesn't like customers disassembling their products. The screw you broke is a very fine screw. Your screw probably broke for one of three reasons:
1) you over-torqued it. With such a small screw, this is easy to do. BM probably installs those screws with a torque-limiting tool to an eact torque spec set by their engineer.
2) you got it cross-threaded. With such a small screw, this is easy to do. BM probably installs those screws with a fixture that assures that the screw goes straight in.
3) you got some foreign object/debris in the threads that caused it to bind up. With such a small screw, this is easy to do. My guess is that the the "foreign object" was actually thread locking adhesive residue that you didn't clean off. BM probably would have cleaned the screw and the hole with a Methlyene Chloride-based solvent to remove such residues and then re-applied the approved thread-locking adhesive specified by their engineer.
Special tools and engineering specs and fixtures and specific solvents and adhesives... Wow! Do you have all that? I sure don't.
There are some things you can do on your BM knife using your BM tool kit such as removing and reattaching the pocket clip, even moving the clip to other configurations on some newer models, and tightening or loosening the main joint on many models. But more extensive disassembly should be left to people who have the special tools, engineering specs, fixtures, and specific materials.
Everyone who is anyone knows that BM's warranty doesn't cover disassembly. It's been that way for years. And, it's printed in big, friendly letters right on the box. If you want a knife that you can disassemble without loosing warranty coverage, then don't buy a BM. It's that simple.
I have one of the first AFCKs sold and I've used the crap out of it. Every time it starts to get dirty, I clean it out with spray solvent. That's all it takes. I like a knife that's so well-designed and constructed that I don't have to take it apart.