Stop screwing around and cut it off with a 4" angle grinder. You cut almost all the way through what is called a relief cut and then put the puller back on. It is difficult at best to cut all the way through without cutting into the steering box output shaft So you stop short the puller will exert enough pressure to use the cut for relief and then it comes off.
When I had to replace my gear box, I couldn't get mine off either. I swear I beat on it for over an hour and PBed it to hell and back again. Finally gave in and called my mechanic buddy. He came by with a 3lb and 5lb mini sledge. Literally three big whacks later he had it off. I told him I loosed it for him. LOL
1996 White ZJ
1987 Maroon YJ (sideways build)
1996 Forest Green XJ
If the reason to get the 15+ yr old pitman off is to put on a new one, I wouldn't hesitate to take an angle grinder w/cutoff to the pitman and put a slit in it to pop it open.
This. I would STRONGLY advise this.
Don't be afraid to apply heat and cold. I'm not saying a fire extinguisher gets REALLY cold when applied properly to parts, but my pitman arm literally popped right off when covered in a little white powder.
Hot and cold do different things to steel. Just saying.
91 YJ, 350/700R4/231, 8.8/HPD30 with 3.73s, 6" SOA with 38" TSLs. If I ever see the previous owner again, I am going to curb stomp that meth-head brain dead crackpot.
I like to put a puller on it and put some good pressure on it, I've got a nice 5 foot spud bar/ straight crowbar, that I thread down between the radiator and grill, from the top (under the hood) and rap on the pitmen arm as close to the splines as space allows. I live in the salt belt and this method has worked great.
This worked. It was 90$ to rent but well worth it. I did cut into it with the sawsall I think that helped too. And the drifting problem is a lot better too. Now to get the drag link adjusted......
What? A $90 rent is 'well worth it'? If all you had was a sawsall you could have bought an angle grinder and a dozen cutoff wheels for that and had change left over, and a great tool for the future when done.