For some future version of me who decides to take the lock mechanism apart to grease or for whatever reason, don't forget to insert the pin on the pawl in the lever. You will save lots of agro. And.... test, test, and test again before you insert the mechanism in the door.

I sturggled for five hours to find a way to open the door. This included taking the working passenger door apart and trying to find a way to duplicate the situation. I was correct when I assumed that I did not put the pin from the pawl in the actuating lever. I was able to confirm this on the driver's door that I messed up.

After a good night's sleep, I managed to get the door panel off on the inside WITHOUT removing the seat. This allowed me full access to the inside of the door. I was planning on drilling a hole in the back of the mechanism and tripping the pawl but decided that there had to be a better way.

I played with the now similarly disabled passenger door actuator but this one was in my hand - not in the closed door. I found that there was just enough play in the pawl that I could trip it with a small screwdriver or the like. So back to the Jeep and the driver's door.

I used a mirror and flashlight to see the far (outside) edge of the mechanism. I even saw the pin on the pawl that was not in the lever. That was the object of my attention. The problem was that even when I held the mirror and flashlight in my left hand, as soon as I put my right hand in the space, I could not see. Now it was McGyver time!

I used some two-sided tape and stuck the mirror on the inside of the outside door panel at just the right angle that would allow me to bounce the light off it and see the "magic" pin. I held the flashlight in my left hand then played with a few items to try to reach the pin. The distance between that outboard edge of the mechanism and the door panel is not more than 2" and this made it difficult to get a nice screwdriver in there. I opted for allen keys and found the "goldilocks" one - just right - that was not too long, not too flexible, and not too big in diameter. It too a bit of maneuvering since I had to do it all in the mirror but eventually there was a satisfying "CLICK" and the door opened!

No holes, no mess (well not much), and no more headache.

I quickly removed the mechanism from the door, disassembled it, confirmed that I did not put the pin from the pawl in the lever, fixed it, reassembled it, tested, tested, and retested before I put it back in the door.

All is well and there was a happy ending to the is adventure that will never happen again on my watch and I would not want this to happen to anyone out there - good or evil. BUT IF IT DOES, remember this post.

Happy motoring....

Mike

 

I've been having the same issue with one of mine, the door is literally stuck, lock linkage broke right off and I don't know where or how or what to try moving inside the latch to get the door open so I can change the mechanism. I have the part and am contemplating cutting the door off and putting a green one on but I'd rather not go to those extremes

 

don't go to such drastic measures yet.

Go to the other door and remove the good mechanism. Study it. You will find a way to activate the stuck door with a bit of ingenuity and patience.

Even sleep on it. That is what I did and came up with the solution next morning at breakfast.

Good luck!

Mike

 

Thanks, I haven't wanted to go that route either but I sprayed the $*** out if it with pb blaster for two days and fought with it for what seemed like forever. The other door was doing the same thing and the lock rod broke off that as well, but I was able to get that door working. (Other side) I should inspect the good latch though like you said and figure out what I actually need to bend or move to make it unlock and open.

 

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