you sound like you have got a fair bit going well done, now to move a character controller to a new position just use the same command that you would to reposition a physx object.
this one
phy set rigid body position ID, x#, y#, z#
using the object number you used to make the character controller.
Quote: "Oh, and on a side note. The vehicle is too sensitive, just walking into it sends it bouncing all over the place and driving into the kerb has the same effect. I set the mass to about 3000 but still no joy. Is there a way to keep all 4 wheels firmly on the ground? "
try
phy set rigid body linear damping ID, value#
Dark Physics makes any hot drink go cold.