How to fix vario panniers?

[Shredder]

I've owned my vario boxes for just over a year, and just went on a trip to the pyrennes. When I came to pack my stuff for the journey home the pannier bar in the left hand pannier didn't work. I fiddled a got it to partially work, but I need to reset it so the full range of movement can be achieved.
Has anyone had this problem before? Should I take the whole thing to bits and rebuild it? Any advice most welcome.

 

[Doofus]

My top box went stiff so you couldn't reduce its size. The mechanisms on either side (i.e the gears and stuff) were fine, it was the sliding overlapping parts between the two halves of the pannier that was sticking.

One half has a deep recess (couple of inches) all round the rim that the edge of the other half slides in and out of. It is a fairly tight fit and tere is also a rubber sealing ring all round so it can get quite stiff.

I split the case (google for instructions - I found some easily)), cleaned the interface and put on some silicon lubricant (not silicone sealant!) and it's now fine.

Apparently getting the two halfs back together can be a game, but mine went straight back together first try (makes up for the final drive oil change re-assembly game I had).

If your one is not stiff, but actually jamming hard, you migh have somthing stuck in the mechanism. You get to see the mechanism when you split the case so you can check this too.

 

[Shredder]

Fixed

I took it to bits and dazlewis is right about fun and games getting it together. However once I slacked off the nuts holding the gears and re-aligned them, I could put it back together and it works. Sorted. Also tightened them up to stop them slipping in future.