My driver’s door will not open now. The key will operate all the door locks up and down but the driver’s door cannot be opened by either interior or exterior handle.
I managed to remove the inside door panel (not easy while the door is closed)
and have used my phone camera and borescope video camera to explore the inside of the door.

Both door handle actuator rods are connected, but nothing I do will open the door. AAA came but was no help.

Does anyone know how to unlock the lock at the door pin itself? Has anyone had the rod from the key cylinder become disconnected at the lock mechanism below? I powered the window down and then up just before the door became unusable, not sure if that was a factor.

Not sure if I should visit a locksmith or a body shop next.

see diagram

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I could be wrong but I think all of the 3rd gen door mechanism are mechanical and only the lock mechanism is a solenoid so its the only electromagnetic part of the door system itself. Is it possible that water got into the door pieces and froze? Maybe in you area it doesn't freeze I am trying to think what could have happened that would cause that area to seize. Either in the lock latch or the electromagnetic door lock itself.

So if you remove the electric lock rod off the door mechanism does the door manually open and close the lock? As it would almost have to be a door mechanism or the electromagnetic lock as these are all ran by rods to and from things..

I had the latch mechanism 'freeze' on a different Toyota ('90 Camry), which was due to the mechanism having dried sticky, dirty grease gumming up the works (it was a 300k+mile desert car...).

If you have the panel off though, you should be able to manually reach in there and move whatever needs to move to open the door. Take off the other door panel and compare what levers and arms move with different operations.

-Charlie

It does not freeze here, and no sign of moisture in the door. I watched Tim’s door actuator repair video. It would seem the death of actuator motor should not affect the ability to open the locking mechanism and not the a door unlatch. As the borescope shows all the rods attached, I am totally stumped.

Timmy’s video has a short “anatomy of the actuator” where he moves each rod etc which is helpful, but still leaves me clueless. And to remove the actuator itself one needs to have the door open, which is the root of my problem.

My point is that dirt and age can cause things to stick too, not just ice.

You have all the tools. Keep at it!

-Charlie

Here's a video by the Expert himself. Once you watch this, you should be able to figure it out. I rebuilt all 5 motors on my Land Cruiser, basically the same process.

Door Lock Actuator Repair (3rd Gen 4runner) - YouTube

The actuators aren't the problem. The door latch mechanism itself won't move for the door to open.

That's kinda what I am thinking.. if you can't manually make it work by disconnecting the power lock rod. I would suspect the door latch mechanism has something wrong.

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Ages ago I saw someone on youtube use a strong magnet (probably rare earth) to help activate a dead solenoid. Might be worth a shot; see if it maybe moves anything around inside the actuator

You might have to take the window glass guide track out of the way to access the latch/ claw It is probably spring loaded and the spring broke, so it's stuck on the u shaped metal piece attached to the opening. if you can get a long screw driver and pull or push the latch claw off that metal bar, the door should open.
A more time consuming prospect would be to go to a pick an pull and get a one and look at it to see how it fits together.

Reach in there and pull the latch rod bud. Pull the rod and push the door open at the same time. If you can’t reach use a pliers or some b.s….. bribe the neighbor kid with small hands if you have too….

Come on hoss. You can do this. It’s just a door. Open that prick up.

Already tried that, many times....BUT!

I think this is the problem.... Toyota door won't open.. easy fix - YouTube

So did you get the door open and replace the mechanism that is broken yet?

Spring could def be the issue - I was chatting w/ a mechanic when I was working in Maine last season and while my door was a busted push rod (lock is still an issue though: '97 SR5 3rd Gen power lock parts query) he said he's occasionally seen the spring be a problem after a decade or two. (^_-)