Well, I just called Alter Ego and they said they won't accept sending back just the defective piece. Which means that I'd have to send the whole damn thing back and chance it on something else being defective on the second one.
But for all those wondering if you can disassemble the Loader to repack without breaking anything, you can and it's easy.
I assembled the whole thing, cables and all and the only trouble I had was with two cables pulling free of the plugs. Easy fix with just a little super glue.
It's best to disassemble the arms by first pushing out the peg holding the back pistons' top joint together near the shoulders, then holding the arm's shoulder joint with one hand and the cab in the other near the joint, with a good tug, pull the arms back out of the sockets. Then pull the pistons out of the lower sockets by pushing them down and to the outside, they should pop right off without any trouble, don't try and pull them straight off.
The legs came off easier then the arms, just grip around the hip joint on each leg with the other hand gripping the lower torso and pull out.
Ripley might be a bigger problem though, I still have yet to disassemble her.
I'd hate for the replacement to be another defective Power Loader. Wish I could just send the defective piece back.