so the ONLY way to get the pin in that holds the dust cover is with the barrel removed?
I've never done it but my AR reference (
Gunsmithing the AR-15, by Patrick Sweeney) says it is possible but not easy.
Here's the text quoted directly from the book:
"Look at the spring that powers the door to see if it was installed correctly to begin with, and if so, to remind yourself how it goes back on. The longer leg of the spring should be pressed against the door itself, in one of the stamped groves of the door. The short leg should be against the upper receiver. The long leg should be closer to the muzzle than the short leg, and both of them should be coming off of the hinge pin from underneath the rod, next to the receiver.
Grasp the old "E" clip at its center with a pair of needlenose pliers, (standard size) and pull it straight away from the upper receiver. Once it comes free (if you're careful you might even be able to re-use it) push the hinge pin towards the buttstock. As the pin clears the front hinge boss on the upper receiver, the spring will lever it up. Keep the cover flat against the upper as you then pull the pin the rest of the way out.
To reassemble, insert the hinge pin through the rear pivot boss and push it into the back of the new door. (The grooved end of the rod goes in first. Make sure the latch is showing on the door.) PUsh the pin halfway across the dust cover opening. Slide the spring onto the pin, with the short leg of the spring pointing up and coming from underneath the pin. Once you have the spring on the pin, press the pin and cover flat to the upper. Now wind the spring one turn (the long leg goes up and away from you, then back down), back to where it started. Press the spring flat into the opening of the cover and push the door pivot pin the rest of the way through the coiled spring. Once it passes through the front pivot boss on the receiver, you can let go of the things for the moment.
To install the "E" clip takes delicate maneuvering and steady hands. The best way is with those two pairs of needlenose pliers. Hold the "E" clip with one set of pliers, not on the center, but closer to an end. (The end towards the handle or top rails works well.) Hold the "E" clip against the groove in the hinge pin. Then use the other pliers to press against the center of the clip, forcing it onto the hinge pin. If you try to hold and push it with just one set of pliers, in the center, when you press it, the clip (obstinate little devil that it is) will pivot away from the pin and not snap on.
Changing with the barrel off is easy: the hinge pin comes out and goes back in from the barrel end. You don't even have to remove the "E" clip from the door pivot rod. Twisting the spring using the short end is a bit more difficult, but nothing compared to the hassle of removing and installing the "E" clip."
The book highly suggests buying and having on hand a number of E clips because you will likely looses a couple in the process. Like I said, I've never done it but it appears to be possible. You might want to search YouTube too. Here's one for example:
[youtube]vHGz4PbyEpA[/youtube]
I'd suggest using a helper with an extra set of hands, lots of light and wear eye protection. Clamp your rifle down as well so it doesn't move at the critical moment.
Best of luck