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Old 03-03-2016, 07:48 PM   #5
6cyl
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Join Date: Jan 2016
Location: Western MA
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So I finally got my door open. It was as easy as:
- Taking apart both doors to study the passenger side latch mechanism then replicating the movement on the driver side. This didn't fix the problem.
- Doing lots of searching online and not finding a satisfactory solution.
- Ordering a Bentley manual which offered no advice except for oil/lube everything.
- Ordering a new latch mechanism from BMW.
- Studying every bit of the new mechanism to see if I could pick my way into unlatching the door from inside the door panel (no such luck).
- Eventually we ended up drilling a few holes in the side if the latch from inside the door to get the pick in to release the catch.

I will take and post a reference photo of where you need to drill the hole if anyone else runs into this issue.

Then installed the new latch. Door works better than ever.

The culprit seems to be crud that built up over the ~18 years / 212k miles this car has been on the road. I think it trapped moisture and when the temp dropped below -10f it froze some part of the mechanism. Then when I tried to open the door something slipped/broke/cracked and wedged the lever that presses on the catch. Even with it out of the car it is impossible to move.
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