S4451-K Gas Cylinder Hardware Kit Installation - chairpartsonline 

Great point! This can be an issue for sure!

Apologies for the delayed response, but we'll reply to help others facing this in the future. The 2" column will stay wedged in the base once the clip is removed and the column pulled off the piston. The column does not need to be removed from the base legs to replace the hardware. It's only shown removed for visual reference. While it's a little more cumbersome to replace the hardware while the column still installed in the legs, it's less hassle than removing the column from the legs first - just to reinstall it. Simply move the base legs containing the column to remove and install from there. So, instead of removing the column, you remove the column with the base attached. And instead of installing the column, you install the column with the base attached. The process is the same, there is just more to move since you're moving the legs and the column together. Need more help? Email customerservice@chairpartsonline.com

Here ya go!: www.chairpartsonline.com/replacement-hardware-kit-for-office-chair-gas-lift-cylinder-free-shipping-s4451-k/

This is a pretty uncommon issue, but you did the right thing. Sometimes if the clip is too tight it means there's a piece of old hardware stuck in the grease in the end of the column which will need to be removed first (pound the column, open end down, on a magazine or something similar until the extra washer falls out). While uncommon, it can be an issue. In that case, though, no washer would fit at all. Sometimes chairs like the Aeron require a thinner washer, and you nailed it with the thinner washer!

Yeah, things get crazy quickly haha. If you get stuck, email us: customerservice@chairpartsonline.com. We understand the chaos, and we're here to help :)

It doesn't need to be sticking out very far to install the hardware. If it's pressed ALL the way in, the cylinder seals are bad and the cylinder will need to be replaced. You can find those here: www.chairpartsonline.com/gas-lift-cylinders/ You only need around 1" sticking out to install the hardware. Hopefully yours is still in good shape! If not, you can find our measuring guide here: www.chairpartsonline.com/measure-gas-cylinder/ Let us know if you need help at customerservice@chairpartsonline.com!

You can get them here: www.chairpartsonline.com/replacement-hardware-kit-for-office-chair-gas-lift-cylinder-free-shipping-s4451-k/ :)

You shouldn't need to add grease unless it's not moving up and down smoothly. If that's the case, just apply a little to the ID of the 2" support column before installing the piston.