really stuck!

[RatLabGuy]

Been there and done that...
Since you dont need to take the pitman off to remove the tie rod end that is spinning, carefully cut the tierod end off with a cut off tool between the center link and the big end of the tie rod end. Center weld a nut to the remaining cut end. (Or clamp it with vice grips) Put a wrench on it, take the castle nut off and drive it out.
Taaaa Daaaah! You are done.

unfortunately this won't work in this case.
The pitman arm has a balljoint on it that goes into the relay rod. THAT is the joint that is bad, spinning in the socket, so I can't get the castle nut off the end of the pitman arm.

Now, *in theory*, I could weld a nut onto the end of the stud sticking out of that castle nut, ad use that for grip to snscrew the castle nut. However since the stud is not huge (IIRC, M14?) only a really small nut could be fit on so that the castle nut would be able to spin over it, like an M6 or 1/4" nut - nut alot of interior space for a weld... but tempting

 

[RatLabGuy]

I used a 3 pound mini sledge and it took more swings than I thought it would but I can off after about 20 mins of effort

where were you whacking it?

Lay about a inch of weld bead on the pitman arm outside of the secter and it should fall off.

Is that just b/c of the heat transfer?
Hell just the practice doing the weld bead could be good for me

 

[MarsFab]

I have removed probably 100 pitman arms that guys say they cant get off, with a hammer and a puller just like yours.
Put the puller on it, get it tight like in your picture and smack it as hard as you can right at the green arrow. Hit it a few times then tighten the puller more. I promise you it will pop right off. It knocks the body of the arm out of shape just enough to pop it off.

 

[RatLabGuy]

Well I finally got it off. Used a combo of all the methods above... ground a big chunk out of it, heated it, pounded it... did like stated above, tightened it, whacked it, tightened some more... it finally started to slide off.

I'm pretty sure it was the extra cusin' that did it. It was really loud that time.

 

[RatLabGuy]

Evidence

Here's a flavor of how the thing looked once off, you can see the chunk I cut out of it.

Also, the reason for all this, nice and bent relay rod. Pre-89, the old ones before the recall, guess that beats snapping.

 

[kaiser715]

I had to fight one a couple of years ago, think it was on a wagoneer. Stuck hard, put the puller on it, cussed, PB'd, hammered, cussed it again...moved on to another project. Two days later, I was out in the shop, doing something else...and bang!...it just dropped off and hit the floor. I'd left the puller on it cranked tight, and it finally decided to let loose.