Door Locked
All,
I just had this same problem, however it was not during a speaker install. It happened after going to the store and closing the DS door. I'll attempt to explain the fix I used. If you get confused, send me a PM and I'll explain over the phone.
1. Remove the seat, real easy 4 bolts
2. Remove the center piller molding. Just pops off easy.
3. Remove all the attached hardward from the inside door panel -- handle, arm rest, control etc...
4. Make sure you have a right-angle blade of some sort to start working the inside door covering loose.
5. Start working the panel loose. You will get about 2/3 of the panel loose, once that happens, give the pannel a good pull. Yes, the panel will slip out, even though it appears to flush with the dash up front. In this process you may break a few of the panel capture studs (not sure of the offical name for these plastic peices)
You should now have the entire door panel off. It can be done.
The problem you are having is not with any of the rods activating the lock system. The problem is isolated to the actual latch unit.
The reason you have full-travel of the outside handle and the inside handle is when the latch is locked, a little metal arm is moved out of the way of the unlocking arm. When the unlocking arm is moved to the "lock position" all the handles will pull up with full travle.
When the latch is in the "un-locked" position, the little metal arm is able to PUSH DOWN on the another metal arm which then presses the "un-locking" arm inside the latch unit and the capture latch is then able to rotate 180 degress and releases the door. (sorry if this is confusing). It takes very little metal arm movement to release the actual latch arm -- 1/8" at max.
The probelm is with the little tiny spring inside the actual latch unit. Over time the spring wears the plastic housing, which in turns allows the spring to travel beyond its range of motion and the end result is that the releasing arm become stuck.
No matter you do -- slim jim etc... you will not get the latch to release. I've tried it all!
The only way to get the latch to release to put a long screw driver or piece of steel bar on to the releasing arm, hit the arm with a good hit. This will "pop" the sping loose with the latch unit and the door will open. In my case the spring actually broke through the plastic housing.
Once you get the door open, you will have to remove the latch unit,(disconnecting all the attached rods) remove the three screws holding the metal cover over the latch unit. When it is open, you see the spring that has gone bad. At this piont you will most likely have to call CDan for a new latch unit (CDan may one in stock). I was able to fix mine by fabricating a metal shim for the spring to sit in. No more spring to plastic chaffing. I also greased all the moving pieces inside the latch unit.
I hope this helps. Like I said earlier, if you more details, drop me a PM and we can talk.
Craig