Warning: Skip to 3rd paragraph to bypass the history and get to the tech part.

Recently purchased an '89 LWB Montero; all original with over 220K miles. It smokes a little, shifts a little rough, has hail damage and a multitude of other problems. I fell in love with it instantly and proudly brought it home only to find the wife with crossed arms and a disapproving stare. Sure, the interior smells a little funny and its not the belle of the ball; not to mention it's questionable past resulting in a title that I had to spend 2 months and $125 to get a bond in order drive it. Nonetheless it has charisma and I believe that it could be a great companion given a chance, a little cash, and a lot of attention. It has to live on the side of the house for now but it's paved and semi-sheltered from the sun and rain; something it appears to have never seen in its lifetime.
So...

I've read a lot on these forums before and after purchasing the yet-to-be-named Montero and since then I have developed a laundry list of things to do to help it along. I've also ripped out ALL of the carpet and the back seat to make way for a future platform/storage/expedition cargo area which is the main reason I purchased it and the one thing that will make the wife warm up to my new stray. After a couple of months of cleaning and airing out the interior it smells *much* better and I have a plan for building out the storage/sleeping quarters. I've also spent a couple of days tracking down blinker/brake light issues so I'm ready to start building out the cargo area.

The problem:
The cargo door did not open from the outside when i bought it but would from the inside. I adjusted the linkage for the outside handle and it has worked fine for the last dozen times. Unfortunately, the last time I shut the door I have been unable to open it again. I've tried everything I can think of:
Push/Pull/Wiggle from the inside/outside
Manually moved the linkage for to unlock/open from the inside with the panel removed, including disconnecting the linkage to make sure I had full range of motion.

It just wonÆt budge! I feel like I could figure it out if I could get it open once but the only access point I can find is behind the door trim from the inside... I've removed the rear light, looked underneath, removed the interior trim, etc. and I just canÆt figure out how to get the damn thing to open.

Maybe if I could use a slim-jim kind of device if I knew what the mechanism looks like? I've also reviewed all of the reapir manuals and although they provide great detail on the side doors I did not see anything about the rear door!

Any and all help is appreciated!

That sucks <img src="/forums/images/graemlins/baby.gif" alt="" />








It sounds like a hands on ,one off, type of problem, Get some one local to give you a hand.

Not sure about on the gen 1 but on my Gen 2's a little plastic lever inside breaks and a new one from the dealer is only $25 for the whole handle assembly (not the cover and lights but the internal part.

Kinda what I was thinking TOASTY. The rear passy doors have both had their interior handles replaced due to fatigue. I've taken the rear one down to lube and adjust it. It looks fairly simple to replace. But, it's likely one of the little plastic bushings on the rods in there that's broken. See if you can get access to them from inside...

So am I reading this correctly that you have the door panel off and can't get it to open? Gentlemen, if he has the door panel off shouldn't it just be a matter of pulling the rod and it shoulsd open? or is the actual lock mechanism what is stuck? can you clarify what you have apart tere pignib?

Thats not what the dealer up her quoted me I think it was more like $60. on the good side its real easy to change

Part 68515

Russ

You're probably right i bought 2 about 5 years ago. Still not bad for what you get and it'll last at least another 10 years, probably 20 for you since you aren't in an arid desert like me.

Thanks for the replies. I guess the actual lock or release mechanism is stuck because I am manually moving it by hand from the inside behind the panel as far as it will travel and the door will not open.



Clip of the lock moving:
http://img294.imageshack.us/img294/4227/img0304.mp4

One question on this diagram:


I assume the rod 68526 attached to part 68501 is supposed to be up (pulled toward the roof) for it to be unlocked, correct? As you can see in the next photo I have disconnected this and manually pulled it up while trying to open the door (although I've tried both ways)



I don't mind paying for a new mechanism but it has to be opened before I can replace it, right?

I'm in a catch-22!

try hitting the door further closed to set the lock further latched. It may not have latched far enough to reset.

That rod is the power door lock actuator. You need to find what it was hooked to and move that to unlock.