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IRON HORSE Seating 4000 Series Backrest Cover Replacement Instructions

The following post outlines the required tools and steps needed to replace your IRON HORSE Seating 4000 Series backrest cover. You may also view the IRON HORSE Seating 4000 Series – Backrest Cover Replacement  video for use as a visual aid by clicking the provided link.



  • 3/8” Long-Handle Ratcheting Wrench
  • ¼” Allen Socket -3/8” Drive
  • ½” Socket – 3/8” Drive
  • 3/8” Electric Impact Gun (Optional)
  • Snap Utility Knife



Step #1 – Prepare Area and Chair for Work

  • Remove the headrest.


Step #2 – Remove Armrests

  • Remove the armrests by unfastening the two (2) 3-¼” Allen socket head bolts securing each armrest.


Step #3 – Unclip and Unzip the Backrest Cover

  • Unclip the cover by pushing the clips in opposite directions.
  • Unzip the backrest cover.


Step #4 – Remove Headrest Guides

  • Remove headrest guides prior to the backrest cover by squeezing the headrest guide tips together and twisting to unlock.


Step #5 – Remove the Backrest Cover

  • Remove the backrest cover by carefully pulling the cover from the backrest foam.


Step #6 – Place Template Bolts for Armrests

  • CRITICAL – place the two (2) 2 ¼” Allen bolts in each armrest’s bolting points.


Step #7 – Replace the Backrest Cover

  • Turn the backrest cover inside-out to ease installation.
  • Install and work the cover onto the foam. Velcro the backrest cover to the velcro track on the backrest foam.
  • Pull and zip the cover tightly.
  • Clip the bottom clips together like the original cover.


Step #8 – Remove the Template Bolts

  • Using the utility knife, cut around the template bolts to secure armrest placement.
  • Remove template bolts.


Step #9 – Reinstall the Armrests

  • Push the black aluminum spacers into the template bolt cut-outs.
  • Holding one armrest at a time, hand thread and secure the armrest. Move the armrest around as necessary to ensure the screws are aligned with the threaded hole.


Step #10 – Install the Headrest Guides

  • Feel for the headrest guide holes by pressing down on top of the chair. Cut the new headrest guide holes using the snap utility knife. Make sure to keep the cuts smaller than the headrest guides – do not overcut.
  • Reinstall the headrest guides. Insert the headrest guides and twist to lock. No part of the cuts should be visible after the headrest guides are inserted.
  • Insert the headrest into the headrest guides.