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I had/ still have this problem. Never got around to fixing it yet. Dosen't bother me enough yet, but eventually I will make it right. I made a thread about it some time ago. This was the most helpfull resposne:
cavediver:
"It's actually a cable driven mechanical device that contracts as the cable is wound in a spool. That is what pushes out the lumbar support. It is not a pump.
The gear is stripped in yours and it needs replaced. If it's under warranty take it in because it's a pain to change it out. I fixed one for a friend of mine and it was making the same noise as yours. From start to finish it took me about 2-1/2 hours and the seat was good as new.
To repair it you'll need to remove the seat and take the side panel off the base to get access to the hinges. You'll need to unplug the power switches from the side panel. Unplug the lumbar power line from the back of the seat base and remove the seat back. With the seat back separated, undo the seat cover and pull it up. There are a couple hog rings that need to be cut to get the cover up. Replacing the lumbar is pretty easy once you get to this point. Assemble in reverse but make sure you have new hog rings or the seat cover won't be tight to the foam.
Take your time, take lots of photos and be careful removing the side panel. It is held by 3 tabs that go into spring clips and they are a pain to pull out and you don't want to break it. Before you put the panels back on, remove the spring clips and bend them back in shape otherwise they won't hold the panel tight.
One more thing, the seat bottom frame has razor sharp edges. You'll need some bandaids before you're done. I know from experience."
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__________________ 2005 Sonic Blue V6
Steeda CAI, Xcal II, FRPP GTBs, Black 18x9 DD Bullitts, SHR Honeycomb Panel, Carbon Fiber Interior, Blacked Out Lights, Sequential Tails, Eibach Pro-kit, Tokico D-specs and a thumpin stereo system.
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