So, I learned the hard way how not to do things today but then figured out an easy way to do it (isn't that always the case). I ordered the front end rebuild kit (well worth it, the parts are great) and took everything apart, pressed the bushings out and was ready to reinstall. I had a mercedes mechanic help with the ball joint pressing, get a jig or find someone with one. It's a pain in the butt. The first time I installed the bushing I used a press with a slightly cockeyed die on it and messed the whole thing up. The bolt wouldn't even go through! Luckily these kits come with two and since this one didn't even look that bad I'm going to just leave the other side alone. There are two methods to getting these things off
1. Light it up with a blow torch and let it burn the rubber out (not recommended for environmental reasons)
2. Cut off the ends with a reciprocating saw (DO NOT CUT INTO THE CONTROL ARM!)
, pop out the caps, then press out the inner bushing with a piece of pipe and a jig to set it on with room underneath. I chose this method and it shouldn't take more than 10 minutes.
Installation actually turned out to be fairly easy, and if you order the kit you are getting a free press as it turns out. So, do your idler arm bushing kit rebuild with the new bolt and hold onto that old bolt. Tap one of the caps in to the control arm (it doesn't have to be all the way, let the press handle that) and lube up the inner bushing with liquid wrench or any other silicone-based spray lube, reapply if necessary during this process. Drop your idler arm bolt through the inner bushing and out the bottom cap, it should protrude about 1/2", enough to get a nut on it. Now start turning and the whole bushing should start sliding in. Get it most of the way in then remove the bolt and get your actual control arm bolt and use it for this step. Put the top cap on and drop the bolt through and start tightening it again. We used a wrench with a pipe on it and a breaker bar on the other end to get it to seat, it will take plenty of force. Check to make sure you have seated the inner bushing into both end caps as it will not be totally seated even after the caps have seated in the control arm. It will take a couple more cranks. And, voila! Instant press. It took about 10 minutes once we figured it out.
I am interested to hear how Ken does it....
~jesse