mtgldr

My lumbar support started grinding on my 2010 so I took it out to see what the problem was. Broken gears.... I figured I'd find a used one at a scrapyard but that seems to be impossible. Ford wants $350 so I decided to setup a fixed position using the cable and stock housing.

No support is not comfortable for me and full support is a little firm for daily use. After you remove the lumbar mechanism you remove the screws in the side plate over the gears. You can see the broken gears in the pic. I took the cable and extended it thru the opposite side of the housing. I then secured it with a cotter pin folded over on itself. With the cable all the way at the end of the housing the lumbar is fully out, if you prefer less support slide the end of the cable up the slot in the housing and you get about 60% support (see red arrow)

I'll keep looking for a used set of gears or support but until then at least I have some support. Hope this helps someone else.

Lumbar removal - I was able to pull the headrest, flip the seat forward and move it all the way towards the steering wheel. I could then access the back of the seat, unscrew the left side trim and remove the support without removing the seat. I found these instructions after I had already removed my lumbar.

http://iihs.net/fsm/?dir=453&viewfile=Lumbar Assembly.pdf