Anyone actually taken the assembly apart and tried to replace the spring? Someone must have tried.
LOL. We talk a lot but not much gets done. And, more than half the time, people don't get back to us to let us know they solved a problem.
Someone who has done a lot of disassembly/assembly on W140s is phamilton01. He also has sold a bit of used parts. May be worth contacting him, but he is usually around, and if he could contribute, I expect he would. Also, there's eddie a for parts.
The thing about the seatbelts is that they are a very important safety item. If they should fail when you need it, that would really suck. If it fails without tampering, at least you could sue someone. I don't know your mechanical ability, but I'd be cautious about disassembling/reassembling one, particularly if it's put together by "stamping" or pressing parts in place. There is also an explosive charge in the mechanism, the pre-tensioner, which goes off, like the air bags, in the event of an accident and rapidly retracts the belt to hold the occupant. Again, I don't know how these things are put together, so I don't know the level of complexity. It could be simple. This is just some cautionary commentary.
I think most of us would like to see a fix for this very common problem. I've been putting off my investigation for a long time.
Brett