Hi There - hoping you can help me. My wife's 2003 MPV's driver side door is stuck. It seems to be the exact problemt that you said you have experienced with the rusty lock mechanism. Can you tell me how you removed the door panel without being able to open the door.
You assistance would be greatly appreciated.
-Karl
I just fixed this same problem. It happened to me 3 different times in a month so I got good at it. Before you dive into removing your door try this. Pull the door handle and release it letting it snap back several times. The problem is a half open door latch that won't let the door unlock. Do this as aggressively as you can to attempt to get the latch to return to its original position. Check the door lock between flicks.
Ok, if that didn't work, here is how to remove the door.
1. Remove the screw behind the door latch, you will have to pop the plastic cover off first.
2. Remove the rubber insert in the door handle
3. Remove the screw that is now visible
4. Now remove the window/lock control module, the back is free but the front has a plastic lip so lift the back up and pull towards the back of the van.
5. Remove the clips that attach to the lock and to the window controls (these can be a pain)
5. (Optional) Remove the bracket that held the window/lock control module
At this point your door is basically free, it is only held in place with plastic clips that can be easily forced off. If your door were open you would simple pull the bottom of the door out (hinged at the window) and lift it off. But since we can't pull because the door is closed we have to force it out.
From here it is pretty simple. Move the seat all the way back and tip the seat way back. Lift the door panel straight up. You will be breaking 2 plastic clips from the rear part but once you do it just pulls out. This is not that easy because the space is limited but just keep pulling and force the rear end of the door panel past the b-pillar. Once you do this it is free.
Have fun and try to keep the black gook from getting everywhere.
Oh, to fix the door lock just oil/grease it and manually move the mechanism several times.
SOURCE: Removing Door Panel for MPV with door Stuck
I think the 04 should be very similar to the 03. Here is my fix for the 03
I just fixed this same problem. It happened to me 3 different times in
a month so I got good at it. Before you dive into removing your door
try this. Pull the door handle and release it letting it snap back
several times. The problem is a half open door latch that won't let the
door unlock. Do this as aggressively as you can to attempt to get the
latch to return to its original position. Check the door lock between
flicks.
Ok, if that didn't work, here is how to remove the door.
1. Remove the screw behind the door latch, you will have to pop the plastic cover off first.
2. Remove the rubber insert in the door handle
3. Remove the screw that is now visible
4.
Now remove the window/lock control module, the back is free but the
front has a plastic lip so lift the back up and pull towards the back
of the van.
5. Remove the clips that attach to the lock and to the window controls (these can be a pain)
5. (Optional) Remove the bracket that held the window/lock control module
At
this point your door is basically free, it is only held in place with
plastic clips that can be easily forced off. If your door were open you
would simple pull the bottom of the door out (hinged at the window) and
lift it off. But since we can't pull because the door is closed we have
to force it out.
From here it is pretty simple. Move the seat
all the way back and tip the seat way back. Lift the door panel
straight up. You will be breaking 2 plastic clips from the rear part
but once you do it just pulls out. This is not that easy because the
space is limited but just keep pulling and force the rear end of the
door panel past the b-pillar. Once you do this it is free.
Have fun and try to keep the black gook from getting everywhere.
Oh, to fix the door lock just oil/grease it and manually move the mechanism several times.
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I am having the same trouble with the passenger side door.
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