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If the assembly gets un-timed, is it just a matter of moving the gear around to get it in sync?
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Yes, however I beleive a fully reclined position is the easier to streatch the hinges that extra inch and a half to slip the rod back in. Also, moving both hinges to the stop point should time them up properly.
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How much additional disassembly is involved to replace the transverse rod?
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The easiest way is to:
1 - Remove seat from car (4 bolts under than slide rails + 1 bolt for seatbelt)
2 - Remove back panel from backrest (handful of screws along bottom)
3 - Remove backrest from seat (3 bolts per side I believe
4 - Unstretch leather by unfastening plastic anchors from the metal frame
5 - Twist hinges to inclined (backrest laying down position) extreem (I could be wrong, it could be the other extreem. Its been 7 months since I did this)
6 - Brute force them apart far enough to remove the transverse rod (the jack and a couple of pieces of wood may work for this)
7 - Inspect transverse rod
-make sure no spiral stretch marks
-make sure the square ends align.
8 - Assembly is reverse of dissassembly (sorry had to
)
Good Luck! Let us know how it turns out!
Scott