Need to replace the pitman arm. What size nut is it? 11/4 too small and 11/2 looks too big. Any suggestions on pullers? Too tight to get generic puller in place.

Well, a lot has to do with what kind of vehicle we are talking about. For future reference, YEAR, MAKE, MODEL and ENGINE SIZE is required information if you want someone to answer questions for your vehicle....
On MOST vehicles it is not required to loosen or remove the gear box to replace a pitman arm. On some vehicles this IS required because there is not enough room to use a pitman arm puller with the gearbox in place. So, basicly. if you can get the puller in there, the answer to your question is NO and if there is not enough room for the puller the answer would be YES.

The idler arm is totally different. Some vehicles have self-locking nuts where the idler arm connects to the center link. Others have "casltle" nuts and cotte pins. The self-locking nuts can be very difficult to remove and ven harder to get back on. The ones with the castle nuts are easier if the cotter pin comes out easy.

As for how long it takes...again, this is vehicle-specific. Most cars take just under an hour each for the idler arm and pitman arm.

You need a ,large adjustable wrench,a 9/16 wrench, a hammer, and a pitman arm puller. It is a special tool that you may be able to rent but will probably have to buy (about $60). With the latge nut removed you put the puller on the old pitman arm and tighten it. When it is tight hit the center tightening bolt with the hammer and tighten again. Repeat until the arm comes off.
If you try to do it without the puller you will wreck the seal in the bottom of the steering box and it will leak. Replacing the seal will require removing the pitman arm again. hope this helps.

You will need a pittman arm puller and a tie rod puller to remove this item. Some shops such as NAPA & Auto Zone rent these tools

Pitman arm requires a pitman arm puller, and a tie rod seperator or "pickle fork". Remove the cotter pin on from the joint on the pitman arm and center link, then remove the nuts from both ends of pitman arm. Use the pitman arm puller to remove the pitman arm from the steering gear, then use the tie rod seperator to remove the end from the center link. Reinstall and retighten nuts, do not leave out the cotter pin.
Idler arm will require tie rod seperator. Remove the cotter pin from the end at the center link, use the tie rod seperator to seperate the joint there. Unbolt the idler arm from the frame, and remove. On reinstalling remember to install a new cotter pin. It would be best to have the front end alignment checked after replacing these parts.

you don't have to remove the steering box to do a pitman arm. Take off the one 1/4 in. nut, or whatever size it is, take the nut off the center link, put a pitman arm puller on the steering box side, and tighten the puller until you can't go any further, and hit the adjuster w/ a hammer hard, then tighten some more and repeat

remove the large nut where it attaches to the steering box, the small nut where it attaches to the center link. you will need a pitman arm puller to get it off the steering box. before you pull it off, take note of the positioning of the arm, there are 4 possible ways to put it on and you HAVE to put it back on the same way. dont forget to get an alignment after.

You'll have to rent or borrow a pickle fork and a pitman arm puller. There is more than one size of pickle fork so specify for tie rod ends. You can buy them too, about $100 for the pair and they are not vehicle specific.
Jack and block up your front end so the wheels are clear. Take the nut off the tie rod end and wedge the pickle fork between the tie rod and the drag link, rap with a hammer until it separates. Loosen the bolt on the collar and unscrew the tie rod end. Count the turns when you remove it and screw the new one in the same number of turns.Fit it into the drag link and tighten the collar and the new nut.
Take the nut off the idler arm and use the pickle fork to separate it from the drag link. Unbolt the idler arm from the frame. The new one goes on in the reverse.
You'll probably need an adjustable wrench to remove the nut from the pitman arm,it's bigger than most wrench sets. Separate it from the drag link first. Slide the puller on and tighten it up. Once it starts to turn hard, give the bolt on the puller a rap with the hammer and tighten some more. Repeat until the arm comes off. Slip the new one on and tighten.
Don't be shy when you tighten these parts because if there is play, the holes in the drag link will oval out and you will have to replace it too. Don,t use a pickle fork on the pitman arm or you will have to replace the seal in the bottom of the steering box. Hope this helps.

You will have to get a couple of tools for this job, a "pickle fork" and a pitman arm puller. You may be able to rent or borrow, but you should be able to buy them for about $80. They come in handy. To do the ball joints, jack up the truck and block it. With the wheel off remove the big nut on the inside of the spindle. Wedge your pickle fork between the spindle and control and give it a few belts with a hammer until the ball joint comes outof the spindle. Don't be shy with the hammer. Next you remove the ball joint from the control arm. IT may be riveted or bolted. Grind the rivets off, with a mini grinder. Bolt the new ball joint into the control arm tight and put it back in the spindle. Tighten up the big nut. If you are using a socket or box end wrench when you can't turn it any more it should be tight enough,put your shoulder into it when you tighten. Do your ball joints one at a time. You can use this procedure to remove the pitman arm from the center link. To remove the pitman arm from the steering box, remove the nut first. Hook up your puller making sure it is centered on the steering box shaft and straight with the angle of the box. Tighten the center bolt. When it gets hard to turn with your wrist give the bolt a sharp rap with a hammer. REpeat this until the pitman arm comes off. Put the new one on,they are usually made so that they will only go on in one position on the steering box. Make sure you before you tighten it that you didn't put it on upside down. When you sure it's on right tighten it up. Itshould return to a similar position on the steering shaft as the old one you took off. Reconnect the other end to the center link. Make sure you grease whatever you replace, and get your truck aligned as soon as possible, or your tires will start to wear funny.

yes you need to unbolt the steering box and drop it a little. not to hard. then you remove the nut and you will have to use a puller most of the time.

The idler isn't bad, Remove cotter pin going through the nut, take off nut, you need a seperator tool to pull apart the arm from the center link, once that is done, remove the two bolts holding it to the frame, remove arm, installation is just reverse.
The pitman arm is a little more to it. Do the same, remove cotter pin, take off nut, and seperate it from the rod, now there is big nut holding it on to the bottom of the steering box, take that nut off (some are a real pain), you will need a pitman arm puller to get it off. Note the position of the arm, need to put new one in same place, pull it off slow, sometimes seals will come with it, put seals back in same way, if they come out. Put some grease on splined shaft, tap new arm on until you can get nut on, tighten up with nut. Hopefully you have any problems. Good luck.