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That rust is pretty typical. The pocket was supposed to be filled with seam sealer to allow water to run out the two notches - which didn't happen all the time. I'd cut and patch as needed, your rust isn't bad at all considering what I usually see here in the northeast.


Many of the replacement idlers have been wrong for ages. The one that was on your car is also a replacement. You could replace the bushings, or get the Rare Parts unit. West Coast Classic Cougar carries the arm.


https://secure.cougarpartscatalog.com/71idler.html?sessionthemeid=26


The tie rod ends should be ES387R for the outers, ES2004 for the adjusters and DS791 for the inners.


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