Here's how to do it:
1. Extend seat belt fully and use a C clamp to hold the belt tension. Do not over tighten the C clamp as you can bend the ratchet mechanism. (DO NOT REMOVE THE BLACK END COVERS...YOU WILL DAMAGE THE SPRING MECHANISM!)
2. Pry the belt end loose using a screwdriver. Once enough slack has been created, use pliers to pull it a bit more so you can cut it off.
3. From the side shown, cut the belt off. There is a steel rod that is sewn into a loop in the webbing. Do not lose it!
4. Remove webbing from retractor mechanism (it isn't easy...you'll have to rock it back and forth and pull hard)
5. Remove the belt and note which direction it feeds through the retractor and which direction the fabric is folded and sewn.
6. Remove the buckle noting which direction it faces in relation to the belt. Feed the buckle onto the new belt facing the same direction.
7. Cut a true end on the belt end where it will feed back onto the retractor and melt the end of the belt just enough so the belt will not fray. It doesn't take much heat to seal it off.
8. Feed the new belt (with the buckle in place) through the retractor and pull about 2 feet extra through the slot to give enough slack so you can sew the end in the next steps.
9. Note how the belt is folded over the steel rod. Leave just enough overlap to securely sew the webbing back together.
10. Sew the end. Use a strong reinforced thread (don't use a cotton thread). I used a compound zig-zag pattern and a straight stitch.
11. Re-insert the metal rod.
12. Pull the webbing taught in the retractor mechanism. Do not leave any slack in the belt end.
13. You will probably need to use a dull putty knife to tap the lapped webbing back into the retractor mechanism. A few careful taps with the hammer will speed up the process without damaging the belt.
14. The belt should look just like it did when you removed it.
15. Hold the belt with one hand and remove the C clamp, then slowly let the retractor feed the belt back onto the mechanism.
16. Reinstall them in your vehicle....note how the small plastic rivet that came on the center seatbelts from a 1996-1998 Voyager/Caravan/Town and Country holds the seat belt buckle from sliding down between the seat and the door. This was a great bonus feature of using the webbing off of this vehicle.
I hope that helps anyone needing to replace your webbing. It took me about 1/2 hour per belt. After doing it myself, I would not pay anyone to do it. However, for those who are faint of heart, the job only took about an hour....depends upon what an hour's labor is worth to you if you want to pay someone to do it for you.
