I read a few threads about this subject before doing mine. Here is how it went, idler came off with very little trouble while leaving center link in truck still connected to pitman arm. A week or so later I attempted the pitman arm. One thread said to use a cut off wheel and cut it off in line with the splines? I did, but I sure as heck was not going to cut into the splined shaft or cut/melt the seal on the shaft either. Well, 3 cuts later and that python was not coming off. Ok, other thread said to leave one bolt in (lose) in the steering box, shift it to get a puller on it, and pull it off. Sorry, no room to get puller in there to pull the arm off.
Finally, I pulled the final 3rd bolt out of the box and shifted the box up as far as I could to get puller on the arm. Started to attempt pulling procedure with nice long box wrench. Uhhhhh, thats a no go. So got the impact out and pulled the trigger. Nothing! Waited until compressor built up fo full PSI and gave it a go again. Finally that pitman arm came off!
Now, I discovered that the steering shaft came out somewhere when I pushed the box all the way up. This was after I turned the steering wheel 180 degrees. Shocked, I turned the wheel back 180 degrees and dropped the box down the whopping 3/4 inch to line up with the box bolt holes. Steering shave must have fallen back in place cuz its been driving for the past 4 days without any lights, etc.
The nut, got a long box wrench and put my feet against the frame and gave it all I got with leather gloves on. Guess its tight enough.
Took the truck in today for life time allighnment and discovered driver front caliper hanging up cuz its all the way out due to pad material down to nill. I know its off topic but new pads/calipers/hardware/pins coming tomorrow.
Oh, took my calipers to the old pitman and seems like there is a big and small end for the splined hole. That thing may have a taper to it thus why it may be such a bear to get off.
Have fun! Its worth it though, nice and tight steering.
2005 2500 CrewCab 4x4
Banks cat/half back exhaust