I'm replacing several steering components (tie rods, drag ink, steering damper, idler arm bushings) on my 1995 E320 coupe and ran into a problem: It looks like I can't remove the idler arm bolt because it will hit against the cat converter on exhaust pipe!

Is there anyway to remove this bolt without having to disassemble exhaust?

The manual doesn't say anything about having to remove the exhaust. I'm thinking of cutting the head off existing bolt and inserting the new one upside down so that the bolt head is under the idler arm and the nut is above it. If I do this I also could drill a small diameter hole in bolt above the nut to insert a cotter pin thru it to prevent bolt from falling out is somehow the nut lossens up.

Also, do I need a special tool to remove the bushings? The manual says I need the extractor (tool # 129 589 00 33 00) and the press-in tool (# 115 589 08 61 00). Is this absolutely necessary?

Any help/advice is appreciated!

Do a search, I think there is a thread around here somewhere showing how to make the special tool. It is easy enough to lower the exhaust. I don't remember off the top of my head but make sure the bolt isn't unique where it can't be replaced with a standard grade 8 fastener if you do end up cutting it. If it is unique you may need to look at a pull a part or purchase oem.

__________________
Jim

Ok - I was able to get the idler arm bolt out without cutting it. The trick is to remove the nut - then remove the top and bottom bushings from the idler arm tube. Once the bushings were out of the idler arm tube - it allowed me to angle the bolt enough to remove it without hitting the pup cat converter on the exhaust pipe. Glad I didn't have to cut off bolt head.

So does that mean that to reinstall all, one places the bolt in the upper bushing and then guides both into position to have enough clearance? Then, insert lower bushing and somehow press in?

I need to do this so I am learning from your experience

I wasn't able to get the top bushing out of my '87 300E, the cat was that close.
I used a sawzall and cut it off. Put a little piece of sheet metal between the bolt head and the cat so I didn't punch a hole in that. Clamped the bolt in an upright position with locking pliers that also kept it from spinning. Put it on upside down with the nut on top. I used the old nut and new bolt to pull the bushings into place.

__________________
1987 300E