I think I really screwed up, door won't open

I was replacing the motor on my door lock actuators, when I made a serious error. I somehow switched the locking mechanism around inside the actuator, so that even when it is unlocked, and the latched is pulled, it will not release the door. Since this is the driver's door, I tried the key as well. Nothing. Oh the key turns, or you can pull the handle on the door (both handles), and work the auto lock or manual lock all you want, but the door will not unlatch.

And the entire latching mechanism is accessed though the side of the door. So no open door means no way to take the actuator mechanism out. The inside door panel is off, so I have access to the inside of the door that way, albeit an uncomfortable way.


Any ideas how to open a Prius door that will not unlatch?

Once the door is open, I can fix everything else. Its just getting the door open.



Right now I'm looking at three different routes:
1) I've ordered a replacement actuator from ebay. When it arrives I'll open it up and see if I can replicate my mistake. Perhaps this might lead to a non-destructive way to open the door. This is doubtful, but the information gathered will be valuable for solution #2.

2) Somehow smash the actuator while inside the door and then reach up in there and pull the proper part to unlatch the door. Remember the inside door panel is off, so I can reach up in there easily enough.

3) Open the B pillar from the inside and cut the two bolts that hold the "U" shaped pin for the door latch. This is the pin on the B pillar that your door latches to. I have no idea what's inside the B pillar and if the ends of those bolts are accessible, or if simply cutting them will allow the door to be opened.

ANY help would be greatly appreciated. Thank You.


The post with the full discussion on fixing the motors for the actuators is here: I think ScottGuth did a great job on the thread. It also has many photos of what an actuator looks like if you want to have a better idea.

 

Well I have to say I'm impressed by the response. However, I see I didn't make myself entirely clear.

The locking mechanism works perfectly, in that it locks and unlocks when its supposed to.
The door latches work perfectly in that they all do what they are supposed to do.

Between the latching mechanisms and the latch itself (that is the metal part in the door that wraps around the U shaped pin) is a linkage for the lock. If you stupidly disable this linkage, like I appear to have done, then when you operate the door handle, it does not turn the latch.

So everything works right up until the point where the lock engages, which is inside the body of the actuator.

Does that make sense?

This is why manipulating the door linkage doesn't open the door, and why a thief can't open it either. If the solution depends upon getting the existing mechanism to work like it regularly does, then it will not work in this case.

 

John, I just wanted to say I gave this a try. I grabbed a new 9v battery and the jumper wires (small wires with alligator clips on each end) out of my electrical tool box, and gave it a go. The yellow and green wires did operate the lock, and reversing polarity did lock and unlock the mechanism. Interestingly enough, if the voltage was left on it would hold the lock closed or open, as in hard enough that I could not manually move the lock lever on the door.

Alas my problem is between the lock at the latch, so it didn't open the door. Worth a try though, and fun in a geeky sort of way.

 

Well I solved the problem, and without doing a lot of damage to the car. I already posted the results on another thread, so if you're interested, here's the link.

Fixed: Door Lock Actuator in Gen II Prius | PriusChat

My solution is near the end.


I want to thank all of you for your input. I appreciate it.