Well, for the longest time it didn't look like it was going to happen to me... But I just looked today, and the little bar under the left side of the the driver's seat has cut through all the cusion, and now a mark is showing up on the fabric... it looks dangerously close to cutting through.
Has anyone had luck with warranty on this? Did you have to take anything to the dealer to "prove your case"?

 

I had it replaced 3 times, no questions asked.
Ford wouldn't let them do anything to permanently fix it, so they said they would replace it as need be.

Before I did my seat mod I got a new set and they let me take them under warranty and I brought my stock ones back about 3 months later when I finally got into the upholstry guy. No problems.

-Kimball

 

same problem, fixed once and just started to have problems again. ford fixed no questions.

 

Where does this happen at? Should it be happening to my 01 with 14,000 miles on it? I only weight about 150 so that should help a little.

 

Mine was fixed no questions asked. It happened in less than six months (I am a big guy.) I had the upholstery shop wrap the bar with padding so it won’t happen again – so far so good.

If you want to completely fix the problem, here are some instructions that I saw on the forum a few months ago. (I haven't dont it - yet.)

Lightning seat Mod for fat people:

We’ll take the seat apart - its very easy:

pull the lumber **** off, it might be hard to get off

unscrew the seat lever

unscrew the two visible screws behind the lever and lumber ****

pull out the x-mas tree in the rear

unscrew two screws under the front of the seats (the plastic cover screws)

unclip the cloth under the front

unclip the cloth on the door side (it can be hard to do, move the seat around)

pull the whole cushion up, don't rip anything!

put 1/2 breaker bar in between the seat and the seat bar and pry it down until it breaks

put the seat back together.

now you've got a nice soft seat!