I fitted the new buckle in under 30 minutes the evening before the car's MOT. With relevant seat out of the car. It took so long because I tried in vain to figure out how to completely remove the plastic shroud panel that covers where the buckle bolts into the seat frame. In the end, because I didn't really have an alternative at that point in time, I ended up carefully making a couple of cuts in the plastic shroud, about 3" long. That allowed it to be pry'd back far enough to let me get a 1/2" drive socket and short extension onto the eye bolt. Later repaired the cuts with black gaffer tape (the rally crew's favourite piece of "always carry" key items, along with cable ties and WD40). The shroud thus repaired remains totally out sight when the seats are in place, between the affected seat and it's neigbour. Remaining 100% functional as its designers intended.
The eye bolt requires a 16mm socket from memory (could be +/-1 different?) and is thread locked (a.k.a. "Loctited") into the into the threads in the seat frame for security. But only with medium strength Locitite. So can be worked free with normal hand tools like a ratchet.
We meet again, old friend! Sadly, we're tossing up how much long the Yeti's worth pouring love and funds into. Gearbox (could be clutch) is getting cranky, a horn failed (they mount those in a shocking spot!), electrics are developing more demons (we've already had the drivers door loom repaired once), and the evaporative purge valve remains iffy (better in the hot seasons here, so we've been able to shelve that problem for the time being).
As for the problem at hand...
One thing that they tried to fail the MOT-equivalent for was a rear seat belt buckle, which was destroyed by a friend by shoving a rather heavy UPS into the back seats without checking what was impeding its path - the buckle quite literally exploded, so we've got the raw metal components of the buckle exposed, and many lone plastic fragments around it. We've got the new spine/buckle from a wrecker, from the same year model and rear seat/side, however as you've indicated VW really went to town on protecting the tri-square bolt from being accessed properly to replace it.
Following the plastic seams doesn't yield nearly as much as we'd expect, and there doesn't seem to be a magic way to unlock the plastic and remove the shroud entirely. We're trying to avoid the technical cut that you've described, however it'd be difficult to get into the bolt, break the loctite, remove the bolt, replace the buckle then reverse, without cutting it.
I guess the reason for posting here today is to avoid making a new thread, and to clarify if anyone knows the midas touch to get this done without having to put the Yeti under the knife? Rego is due in less than a fortnight, and an inspection is required - the local place did a "fail then pass" last time, with the pass coming on sight of a sealed box - ie. we'd bought the buckle, and they were so tired of the problem that they trusted us to promptly fit it. We aim to impress.
Hoping for some insights that'd help us get this done without surgery.
