Last week I was adjusting the lumbar control when it failed in a big way. During the final adjustment, it made a popping sound, then got stuck with the buldge in a very low position that made driving very painful on my lower back. The motor still made its noise but had no effect on the lumbar support control.

Today I pulled the seat apart. This video really helped in that part of the job:

http://www.motorz.tv/blog/2579/musta...ther-interior/

Once I pulled the seat cover off, it became clear that the lumbar had over extended beyond the low point on the adjustment rack. It had popped one of the four bushings off its track and allowed the lumbar mechanism to slip below the lowest intended positon. A cheesy design for sure. The motor is attached by a plastic mounting bracket...that had broken off too.

It seemed like a fairly straight forward repair. I popped the bushing back in place, straighted the bent metal at the bottom of the bracket and realigned all four rods and bushings. I used some dry-lube on the rods then zip-tied the motor to the seat frame.

I decided to position the lumbar mechanism in the full "up" positon. This was done just in case there was something else wrong with the motor or cable, that would at least put the support in the correct part of the seat.

After putting everything back together and reinstalling the seat, the adjustment would still not work. The motor made its sound but there was no effect on the seat. Sure enough, the cable must have been broken or slipped off the track inside the motor assembly. The good news is that the lumbar is now positioned in the perfect middle of my back. There should be no need to adjust it from now on.

The entire job took me about 3 hours. Despite the end result, it was still worth the effort. I took some pictures during the procedure but can't find a suitable hosting site to post them on.

Hope this helps anyone else experiencing similar issues.