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There are three "pins" on each side that activate with the sliding adjustment bar. Check yours, I bet these pins aren't seating properly. No matter which position (front to back) I put the passenger seat in, I can't get all 6 pins to fall in place - hence the noise.
Great news for you BuckeyeKev! Do you happen to have a software revision number on your invoice that you'd be willing to share? I'm certain that my situation is software related, not mechanical.
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