2003 Tacoma Door Won't Unlock

My problem is the driver side door will not unlock, either with the key or by pulling the plunger lock upwards. The plunger moves maybe halfway up but does not unlock the door. So, I cannot open the door to completely remove the panel.

If I slide and recline the driver seat I can pop out all the panel retainers except the ones near the dashboard. The forward end of the door panel, below the manual mirror adjusting handle, is wedged between the closed door and the left end of the dashboard. I can pull the rear end of the door panel away until it hits the side of the driver's seat.....maybe 5 inches at most. That's far enough to barely get my hand inside the door and feel the back of the lock cylinder but not enough to actually see what I'm doing. I've replaced both outside handles before but always re-used the original lock cylinders. If I could just remove the blasted door panel to provide vision and dexterity I'm sure I can fix the lock problem.

At this point I don't know if the problem is with the lock cylinder itself or with the linkages. Ever run into THIS problem, and if so how did you deal with it?

 

Just guessing here, but I’d try a new key. My 06’s key wore out.
Then try some lube thru the keyhole.
If still no luck, could try an inspection camera (snake) to possibly help you see any issues. Maybe help you aim some lube in behind the panel. Good luck!

 

I've seen the same on here before. Don't remember what the solution was however. Seems I recall needing to remove the seat (through the passenger side) to make a little more room for the card to open up a bit more. Might need to take out the lower portion of the dash to make some room as well. I've done it several times but don't recall the steps. Pretty straight forward, just a few screws and clips.

 

I just went through this a couple weeks ago..
You have to take the drivers seat out, I did what you did and tried everything to keep it in, but in the end that seats got to come out. Once the seats out, you'll have the door card off in 5 seconds. Its only 4 bolts and a harness to pull the seat.
Once the door cards out, you have to reach through the door to the latch and start basically blindly screwing around with the rods until the door opens.
There's a write-up on it here: https://www.tacomaworld.com/threads/1st-generation-tacoma-door-will-not-unlock-solved.469156/

 

Thanks, guys. I'm now resigned to having to remove the seats. I've got to get this fixed before the end of the month because my State Inspection and registration renewal is due!

 

By the way, I did try my spare key. Still wouldn't unlock. I'll remove the seats this afternoon so I can remove the door "card." I've never heard the panel called a card but a couple of people here have used that term.

 

Yeah that CARD thing is new to me! Maybe you should also look under the bonnet!

 

Just to follow up, removing the seats was easy (4 14mm bolts per seat) and allowed sufficient room to remove the door panel. I fully expected the spring behind the window channel to be broken but it was intact. The culprit was the handle itself...the plastic loop into which the end of the metal part is secured was broken, allowing the linkage to slip down just enough to misalign the locking mechanism below. Fortunately, I had bought a pair of aftermarket handles 5 years ago when the passenger door messed up, and kept the driver side handle on hand for a rainy day. It poured earlier this month!

Only problem I encountered was the new handle's 1/8" plastic slot which the lock cylinder's metal tab slips into to lock itself in place was too narrow. I had to use a Dremel tool and cutoff wheel to widen it a few thousandths. Oh, and the door's left linkage was a bitch to secure to the handle with the plastic locking clip. No problem getting the linkage in the hole, just couldn't get the clip to lock it in place. I tried various tools including long needle nosed plier with the angled jaws. Finally was able to get the clip to lock by forcing my fingertips far enough in there to pull the clip forward and lock. I've watched a few YouTube videos where the presenters also struggled with that clip.