KekseKaempfer
6th August 2007, 22:26
I braved the potential destruction of my passenger seat for this one, AND took some useful/not so useful pics too! Someone might find this useful anyway.
HOWTO: Replace a broken seat cable (2002 New Beetle)
You will need:
Replacement seat cable. Part No: A1J0 881 595 B (Same component for each cable according to the dealer) £4.73 + VAT
Pointy nose pliers.
Good grippy pliers.
A torch (maybe).
* 1 pan head screw and a washer.
A lot of courage and a swear box.
A small helper.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/0-newCable.jpg
To begin with, you will need to remove the plastic trim around the seat hinge. Gently prise off the recliner knob and then remove the external and internal plastic trim (the internal one you can just leave dangling as it is attached to the airbag cable.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/1-RemoveReclinerButton.jpg
You will now be able to see the hinge mechanism, and probably the broken cable.
At this point it will be helpful to tilt the seat forward. You'll need to grip the broken cable with pliers and pull at the same time as lifting the lever on the seat.
You will now be able to get at the underside of the seat back. Put your finger under the fabric join and gently pull to ease the clip that holds the two sides of the fabric together. The plastic clip is long and runs along the length of the join of the fabric. The two pieces will just separate.
Here is where it gets scary, but don't worry, you won't be able to rip anything, unless you are REALLY rough.
You now need to start to pull/roll the fabric and sponge of the seat back cover up. Gently ease the bottom of the fabric up. You will get to a bit up the seat bolster and then have to do some unclipping.
Looking at the bottom of the seat (sitting on the back seat) you will see two wires which are clipped into the seat frame. These hold the front cover down on the frame. Using a pair of strong pliers, grab both of these wires and unhook them. They have a double bend in them.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/2-seatFrameWireClip.jpg
(this pic shows the clip part way out)
Looking up the back of the seat you will see that the rear fabric is held in by a horizontal metal bar which is held on the left and right to a sprung frame. You will need to unhook the bar to free the cover.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/3-lowerSprungFrameclip_desc.jpg
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/3a-insideFrame_desc.jpg
Once the lower clips have been unclipped, continue easing the cover up the seat. Further up you will come to two elastic clips and two plastic clips, just unhook these and continue to roll the fabric up. It'll be a lot easier once the cover is over the seat bolster.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/4-seatBackElasticClip_desc.jpg
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/5-smallPlasticClips_desc.jpg
I rolled the cover up until just under the lever mechanism (this is where the next horizontal metal rod holds the rear fabric to the sprung frame). I used the cover to hold the lever down so that I could access the cable with a bit more ease.
Using the pointy nose pliers, unhook the broken cable from the lever in the seat back (and the seat base if you haven't already done that). You might need a torch.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/6-removeCable.jpg
Following the broken cable down, push the centre of the small white 'post' guide in (from outside of seat frame in) and remove it from the seat frame.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/7-smallPlasticGuide_desc.jpg
To get the lower plastic guide out, you are going to need to take out the recliner rod (the rod that the recliner knob is attached to).
Looking at the inside (nearest to handbrake) of the seat base, you will see where the recliner rod comes out. There are four bent over metal clips, you are going to have to bend these back. * NOTE these just broke when i did mine. I'll describe how i repaired it when we finish the job.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/8-reclinerClips.jpg
Once you have broken the clips off the recliner rod, remove it. This will allow you to remove the lower cable guide.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/9-brokenReclinerClips.jpg
So you now have the snapped cable out, time to put the new one in.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/10-oldCable.jpg
Using the pointy pliers attach the new cable to the lever in the seat back. If you pull the lever down as far as it will go, it is a bit more accessible. It wasn't that tricky to do in the end. Again, a torch might help. The cable goes through the lever from front of seat to back.
Insert the small white 'post' guide into the frame and push the teeny button in to fix it in place. The lower guide is easily fixed in place by offering it up the the hole at about 45 degrees from how it should sit and then twisting/rotating it clockwise into place. You can then attach the bottom of the cable into the catch on the seat base.
Test the lever, to make sure it is in working. You should have a newly fixed seat you can tilt forward. So the cable is fixed, now you just have to re-assemble the seat.
You need to fix and re-assemble the recliner rod first, it's easier to get back in if you can see where you are putting it.
Find a screw and a washer. The screw needs to be big enough to grip when screwed into the end where the metal clips broke off. The washer just needs to be big enough to stop the recliner rod pulling through the seat. It might help to squash up the broken end with pliers to get the screw to fit a bit more snugly. Insert the recliner rod back into the seat and through, then simply screw the screw with washer into the end.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/11-fixedReclinerRod1.jpg
Ease the seat cover back down, re-attaching clips as you go. The two wires that fix into the base of the seat frame have a double bend and have to go back in on the second bend and not the first, you may need to just pinch up the bend in the wire with your pliers to get it back in securely.
Once you have the clips and what not back where they should be, you can re-join the fabric of the seat cover together. I found it easiest to recline the seat forward a lot and tilt the seat forward too. Give both the front and back parts of the cover a good pull, this not only helps to tighten the fabric on the seat but also makes it easier to get the clip on the cover back together. Start from one of the sides, push the rear clip into the front. Once you have a section in place you should just be able to work along pushing the two fabric pieces together.
Once the cover is back together, put the plastic covers and the recliner knob back on.
Job done, you just saved yourself 2 hours labour, and it only took you 1 hour and a bit. Take the money in the swear box and go and buy youself a few pints.
HOWTO: Replace a broken seat cable (2002 New Beetle)
You will need:
Replacement seat cable. Part No: A1J0 881 595 B (Same component for each cable according to the dealer) £4.73 + VAT
Pointy nose pliers.
Good grippy pliers.
A torch (maybe).
* 1 pan head screw and a washer.
A lot of courage and a swear box.
A small helper.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/0-newCable.jpg
To begin with, you will need to remove the plastic trim around the seat hinge. Gently prise off the recliner knob and then remove the external and internal plastic trim (the internal one you can just leave dangling as it is attached to the airbag cable.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/1-RemoveReclinerButton.jpg
You will now be able to see the hinge mechanism, and probably the broken cable.
At this point it will be helpful to tilt the seat forward. You'll need to grip the broken cable with pliers and pull at the same time as lifting the lever on the seat.
You will now be able to get at the underside of the seat back. Put your finger under the fabric join and gently pull to ease the clip that holds the two sides of the fabric together. The plastic clip is long and runs along the length of the join of the fabric. The two pieces will just separate.
Here is where it gets scary, but don't worry, you won't be able to rip anything, unless you are REALLY rough.
You now need to start to pull/roll the fabric and sponge of the seat back cover up. Gently ease the bottom of the fabric up. You will get to a bit up the seat bolster and then have to do some unclipping.
Looking at the bottom of the seat (sitting on the back seat) you will see two wires which are clipped into the seat frame. These hold the front cover down on the frame. Using a pair of strong pliers, grab both of these wires and unhook them. They have a double bend in them.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/2-seatFrameWireClip.jpg
(this pic shows the clip part way out)
Looking up the back of the seat you will see that the rear fabric is held in by a horizontal metal bar which is held on the left and right to a sprung frame. You will need to unhook the bar to free the cover.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/3-lowerSprungFrameclip_desc.jpg
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/3a-insideFrame_desc.jpg
Once the lower clips have been unclipped, continue easing the cover up the seat. Further up you will come to two elastic clips and two plastic clips, just unhook these and continue to roll the fabric up. It'll be a lot easier once the cover is over the seat bolster.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/4-seatBackElasticClip_desc.jpg
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/5-smallPlasticClips_desc.jpg
I rolled the cover up until just under the lever mechanism (this is where the next horizontal metal rod holds the rear fabric to the sprung frame). I used the cover to hold the lever down so that I could access the cable with a bit more ease.
Using the pointy nose pliers, unhook the broken cable from the lever in the seat back (and the seat base if you haven't already done that). You might need a torch.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/6-removeCable.jpg
Following the broken cable down, push the centre of the small white 'post' guide in (from outside of seat frame in) and remove it from the seat frame.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/7-smallPlasticGuide_desc.jpg
To get the lower plastic guide out, you are going to need to take out the recliner rod (the rod that the recliner knob is attached to).
Looking at the inside (nearest to handbrake) of the seat base, you will see where the recliner rod comes out. There are four bent over metal clips, you are going to have to bend these back. * NOTE these just broke when i did mine. I'll describe how i repaired it when we finish the job.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/8-reclinerClips.jpg
Once you have broken the clips off the recliner rod, remove it. This will allow you to remove the lower cable guide.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/9-brokenReclinerClips.jpg
So you now have the snapped cable out, time to put the new one in.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/10-oldCable.jpg
Using the pointy pliers attach the new cable to the lever in the seat back. If you pull the lever down as far as it will go, it is a bit more accessible. It wasn't that tricky to do in the end. Again, a torch might help. The cable goes through the lever from front of seat to back.
Insert the small white 'post' guide into the frame and push the teeny button in to fix it in place. The lower guide is easily fixed in place by offering it up the the hole at about 45 degrees from how it should sit and then twisting/rotating it clockwise into place. You can then attach the bottom of the cable into the catch on the seat base.
Test the lever, to make sure it is in working. You should have a newly fixed seat you can tilt forward. So the cable is fixed, now you just have to re-assemble the seat.
You need to fix and re-assemble the recliner rod first, it's easier to get back in if you can see where you are putting it.
Find a screw and a washer. The screw needs to be big enough to grip when screwed into the end where the metal clips broke off. The washer just needs to be big enough to stop the recliner rod pulling through the seat. It might help to squash up the broken end with pliers to get the screw to fit a bit more snugly. Insert the recliner rod back into the seat and through, then simply screw the screw with washer into the end.
http://i187.photobucket.com/albums/x319/KekseKaempfer/seat%20repair/11-fixedReclinerRod1.jpg
Ease the seat cover back down, re-attaching clips as you go. The two wires that fix into the base of the seat frame have a double bend and have to go back in on the second bend and not the first, you may need to just pinch up the bend in the wire with your pliers to get it back in securely.
Once you have the clips and what not back where they should be, you can re-join the fabric of the seat cover together. I found it easiest to recline the seat forward a lot and tilt the seat forward too. Give both the front and back parts of the cover a good pull, this not only helps to tighten the fabric on the seat but also makes it easier to get the clip on the cover back together. Start from one of the sides, push the rear clip into the front. Once you have a section in place you should just be able to work along pushing the two fabric pieces together.
Once the cover is back together, put the plastic covers and the recliner knob back on.
Job done, you just saved yourself 2 hours labour, and it only took you 1 hour and a bit. Take the money in the swear box and go and buy youself a few pints.