I'd just like to point out that I called this. When I ordered the True Fit to play with I said the harness was too wide to fit smoothly through the buckle tongues and would fray. I'd most definitely call Learining Curve. They need to re-design the buckle tongues. I'd file a form with NHTSA too. Many people wouldn't know that it is a safety issue.
The True Fit isn't alone in using narrower buckle tongues for the harness straps. In some seats it's a purposeful design - the Radian is one such instance. I've seen one case of fraying with the Radian that is something I would've been concerned about, but the other pictures I've seen haven't been anything I would consider more than fuzzing. The amount of strength the harness has to maintain after abrasion testing is very high, and abrasion testing is pretty serious - not anywhere near what you'd get from sliding the tongues back and forth on the harness during normal use over a short period of time. (And really the point of the narrower buckle tongues is that they don't slide down the harness, so that they're in the position you want them in all the time and you're not digging them out from under a kiddo's bum.)
So that's why I'm wondering if it's more fuzzing or serious fraying. :thumbsup:
I think at this point it's very early to jump the gun and say that the straps are going to become dangerous because of narrow buckle tongues. Sunshine kids moved to just giving people who requested them wider buckle tongues to not have to deal with the complaints, but most people don't replace the tongues on the radian and most people don't have problems with the harness fraying. Seems to me there was another seat that is narrower too?
Anyways, it's very premature to push any kind of panic button about this IMO. I'd still love to see pic's of what the OP is experiencing though - pictures could always change my mind about how serious it is. (Although I wouldn't immediately jump to the buckle tongs being the cause either.)