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1. I noticed when that the threaded bushings on my PV 444 (1957) control arms also have a lot of play. Besides this, the bolts are very corroded and worn. Because of this, I am replacing the metal and rubber bushings, and the bolts with new ones.
Worn threaded bushings
2. What happened to question #2? :)
3. Like you suggest, it is probably reasonable to only replace the inner bushings and rubber seals on the upper control arm. Don't know if the pin needs replacing.
Control arm repair kit
Rubber bushings
4. Haven't crossed this bridge yet. We may get to it this weekend...
5. Rebushing the idler arm is a good idea. We did not even consider switching from a 444 arm to a beefier 544 arm...but then again we don't have a spare 544 parts car lying around. :) The idler arm looks in very good shape and appears even nicer with a fresh coat of paint:
Idler arm repair kit
You may also want to consider inspecting and replacing the king pins. Mine are shot:
King Pin repair kit
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