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Joined the forum because I just bought a 2014 xuv 550. It has 74 hours on it, and came with a snow plow. The previous owner had identified that it was hard to shift so I have already been using the forum to work through that issue. The clutch is removed and now I need to get it packed up and shipped to the clutch doctor. I appreciate the work around clutch puller solution, and to sympathize with others who might have done this, I did cut the 1/2 inch bolt at just the wrong length where I couldn't get the 9/16 bolt into the threads, but I couldn't get the 1/2 inch bolt back out because my magnetic pickup tool was too big in diameter to fit in the hole. I was able to borrow a magnetic tool that was smaller in diameter to get the 1/2 inch bolt out.

The other issue I have found as I've been taking off the clutch is a couple rust issues. I'm guessing this is because it sat in an outdoor shelter that didn't have a floor, but I'm not sure.

1. The torx bolts holding the plastic panels - some of the heads have rusted so the screws are stripped and I can't get a couple of them out. I tried drilling into one of them to use a bolt extractor, but have not been able to drill down into the screw. Are the screws especially hard? This particular screw is the one right in front of the seat on the floor. Any suggestions on getting these screws out? Any suggestions on buying replacements - should I get the same thing from Deere or is there a better alternative?

2. Quite a bit of rust on the silver pan on the bottom of the bed. I have the pan removed and was thinking of wire brushing it down, using phosphoric acid on it, and spraying it with some Rust-Oleum. Anybody else have rust issues on this pan?

Also, the Gator has the bench seat and I've read how the back frame of the bench seat has to be removed in order to remove the air intake housing. Are there instructions somewhere on removing the back seat frame for the bench seat version?
 

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Impact driver with a new torx t25 bit is your best bet, if you dint have a fitting one dont even bother.
Ive seen some really stuck so its not uncommon.
If you drill them, drill them with a sharp drill, drill a bit and swap to the other ones to prevent the plastic from melting and go all the way around.

We dont live in a cold climate so we dont see rust here but i presume the heat is causing the pan to rust. No problem as its only a heat shield.
If you can get owatrol oil anywhere just slather that on.

The bench seat frame is held on by only 4 18mm bolts and a counter nut.
Youll need to remove both side plastic pieces to get that out.

Lastly if you open everything, you can tune this engine a little once you have it open anyway.
There are high rev kits availaible online for the briggs vanguard
 
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