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A lot of impact drivers come with a No 2 phillips head bit. What you want for that sized screw is a No 3 bit. Unless it is really flogged out the correct bit should still do the job.
Also, did you make sure the impact driver was locked in the correct direction before hitting it with a hammer? You have to pre set them to go either left or right. Also, you should turn the impact driver slightly in the direction you want the screw to turn to give the driver a bit of preload, and then give it a hit with the hammer. I have used mine dozens (if not hundreds) of times - especially when working on motorbikes - and have never had an issue, even with the most stubborn of screws.
Possible idea here Njrqs Mate?
Try a solid 10mm -ish punch/real smack ( no greater than the size of your pan bolt head) to shake up the OEM paint and years of great service.
Truly just did this the day before last on an old Louisville twuck swapping sides as they no longer make em :-(
been using a punch to turn bolts/screws sorta like the old cold chisel trick for nuts. i also have a removal kit that u drill a hole hammer a bar in then slide a nut onto the bar, works unlike easyouts.. but i must say the punch trick works better than the extractors i've tried.