You shouldn't have a big issue with sight alignment reinstalling the flash hider/sight assy. as they have splines to align them. Once you have reinstalled the flash hider/front sight assy and properly snugged the castle nut there shouldn't be any play; it should be about where it was when you took it off. The splines should be snug enough that the front end won't just fall off; you'll probably have to gently tap it with a soft face hammer as you loosen the castle nut, at least to start.
Also, FYI, there's a small set screw that locks the castle nut in place; be sure to loosen it before you try to loosen the castle nut.





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