Took a short break from the books yesterday, and decided to repair the broken drivers side lumbar support (the manual one, with the knob) that broke 3 or 4 years ago. I read an article somewhere on the net, so i cant take credit for the whole thing, but I can simplify it for you. The whole thing took about 20 mins.
Its pretty straight forward. You pull the knob straight out (mine was loose anyway, so it didn't have any resistance). Then remove the 2 screws from the black "cup" underneath, followed by the 2 screws from the white "cup" under that one. There is a locking pin that has to be pushed to turn the remaining black plastic through the the frame (away from you). It will help if you pull up the back of the seat cover, approx half way up the seat (otherwise its like doing heart surgery while going in through your ***hole). Once its removed, pull the black housing out through the back of the seat. My lumbar support was broken where a white plastic "screw" met up with the lumbar support (i have no idea why this was engineered that way, as it seems like an easy location for a break). Trust me, you'll know what I mean when you see it.
Take the "white screw" with the broken end, and drill out a small enough hole for an eye bolt to fit in. What we are going to do is use the eye bolt as a MUCH stronger replacement for the original P.O.S. plastic setup. I happened to have an eye bolt laying in the drawer that worked (I did, however, need to cut a piece of the eye out, and crush it down, making the eye bolt part small enough to slide back into the housing). I would say a bolt with the threading for 1" to 1 1/2" should be long enough. Once you have the bolt screwed securely into place (maybe a drop of glue to ensure it doesn't come out, though doubtful), slide it into the black housing that is still attached to the lumbar support (the lumbar support is essentially a band that goes from one side of the seat to the other). There will be a locking pin on the band that will need to be pulled out so the eye bolt's hole can be slid in. When you have the pin reinstalled, just reverse the disassembly instructions to put it back together. Congratulations, you not only repaired your lumbar support for under $1, but you ensured that this part wont break again!
1) This is MUCH simpler to do once you actually take it apart, than just reading my instructions. (at least it was for me, as I'm a visual kinda guy
2)I'm undoubtedly going to get someone to post "this thread is useless without pics". I know
. I would rather post this with no pics, than not post it at all.
If anyone has any questions, or a way I can make this clearer, just let me know.