Fix is very cheap ($1.29 in parts at Ace hardware)
This happened to the center console mechanism of my 2009 JSW about a week ago.
Fortunately, the fix is much cheaper than you think. There are 2 small nylon dowels (pins) that are held into a hole on either side of the hinge mechanism, with springs. The dowels ride in a track of an aluminum casting. The failure is that they shear off.
To fix, you have to remove the front and rear portions of the center console, along with the inside cover of the console lid (combination of snap fits and screws). Then, remove the 2 shoulder screws that are at the main pivot of the hinge (be careful not to let the 2 wave springs and plastic bushing fall inside the works when you pull out the screws). Remove the lid assembly, take out the failed pin, replace with a new piece
(I cut a 10 mm long piece of 1/8" diameter brass rod from the hardware store, since I could not find a nylon rod (brass will last longer). I chamfered the end of the pin that will engage with the track, so that it cannot dig into or get stuck on the track it will ride in.
To summarize, my low-budget DIY (sorry, no pics)
1. Pry the flat plastic cover off that is directly under the Center Console lid.
2. pry off the small plastic cover underneath it. (google 1K0898207 for an image)
3. pry off the small square cover that sits above the Aux jack inside the console. remove screw that sits behind it.
4. pry the aux jack receptacle out of the console, and unplug its connector.
5. open the AC receptacle door (if equipped), pry off the cover that sits over the outlet. pry (from both sides at same time) the entire receptacle plate from the top. remove screws behind upper covers of same plate.
6. pry off the rear portion of center console
7. remove screws on side of console that are now revealed
8. carefully rotate and pull center console up and off of the floor, set aside
9. remove shoulder screws from either side of hinge, saving 2 disc washers and plastic bushing (note assembly order)
10. pull lid assembly off, dowel pins will come out of track inside of small castings. Take care not to lose pins and springs that are behind them.
11. Install newly made pin (I just replaced both right away).
12. Grease track that pin follows
13. Re-install lid with shoulder screws and washers. Open and close lid several times until you are satisfied that it works correctly.
14. Put everything back together in reverse order.
Congratulations. You just saved yourself a bundle!
P.S. - If I forgot any steps, please let me know and i will correct the post.
