There probably is a scene with Frodo and Sam disguised as Orks, the mouth of sauron, the Rohirim Drinking Game, a bit more combat between Aragorn, Legolas, Gimli and the Wraiths. The houses of healing and Saruman are confirmed.
About the length: PJ stated somewhere, that they had to cut out about one hour to bring it down to the cinematic length and that the EE would probably at least that long. In an interview afterwards, he said something about 50 min. As far as I have heard/ read, he never mentioned something about 1.5 hours.