Originally Posted by joycesjag

Problem, rear door will not lock/unlock except manually. I can hear the actuator motor run but lock does not engage or disengage.

First off I am going to say that this is a mechanically intensive repair. Out of all my DIYs, this one was the most difficult. May be not so much as just replacing the actuator motor/lock mechanism but I repaired the broken plastic gear, (we will see how long it holds up). There are many parts to the repair side of things, which there are no parts break down and I had to figure what went where.

It is very possible that you will break somethings that are important and somethings not so important. Also may end up scratching some parts. Proceed with caution!

I would reccomend that you have JTIS or alldatadiy available. There are a few smaller steps that I do not cover.

Drivers side (US) rear door actuator locking mechanism part # XR853056 $292.00. I did not try to cross reference.

Difficulty level: Difficult (see above)
Tools needed: T30 and T15 Torx drivers, regular & phillips screw driver, ratchet with 8mm and 10mm sockets, (extention optional), trim panel removal tool (I use a painters 6 in 1), masking tape, flashlite. Better have some Band Aids close by (optional but needed) .
Time: 3 hours if replacing with new actuator locking mechanism, 4 hours if repairing actuator gear.

Attachment 167706

Lets start off:

Remove the interior door handle trim (cup). Gently prying from front to back. Remove T30 screw that holds interior handle assembly to door skin.
Attachment 167707

Remove the 2 phillips screws located in the armrest.
Attachment 167708

Remove interior door trim panel using panel removal tool of choice. Disconnect 2 wiring harnesses. Remove the 4 speaker 10mm bolts, remove speaker. This gives you more work room.
Attachment 167709

Carefully peel sound proofing from door skin, working from top left diagonally down to expose cut out. It is not necessary to remove entire sound proofing.
Attachment 167710

Now look for this piece somewhere in the bottom of the door. If you cannot find it, time to purchase a new actuator locking mechanism. STOP NOW!!
Attachment 167711

Assuming you have found the part, let the fun begin!!

The quater window and track will have to be removed (not fun). Remove the lower track 10mm bolt from support. Remove 2- 10mm support nuts. Remove support.
Attachment 167712

Remove 2- 8mm nuts from upper quarter window. CAREFULLY remove quarter window and track.
Attachment 167713

Remove 1- T30 screw inside door skin.
Attachment 167712

Time to remove exterior door handle trim. There is a tab that MUST be pushed forward to unlock the trim from the door! I BROKE THIS TAB. In the following pictures I tried to expoxy tab back on but it did not work. I ended up using 3M tape to resecure trim piece, remember there is a front T30 secrew that holds it firmly in place.
Attachment 167715

Attachment 167716

Attachment 167717

Using masking tape protect exterior door handle, 2 to 3 layers works best. Remove the exterior T30 screw.
Attachment 167718

Remove the 3 T30 jam screws.
Attachment 167719

CAREFULLY remove exterior door handle, actuator locking assembly as 1 piece. I DO MEAN CAREFULLY! Slide red electric harness lock back push tab to release electric connection (not pictured).
Attachment 167720

Attachment 167721

If replacing actuator lock mechanism, reverse above proceedure, your done. Easy it is not.

The following pictures are provided for entertainment. As you will see there are many small pieces that are crucial to be replaced correctly and in order! I used a "plastic welder" expoxy with a holding strength of 3500 psi, the most I could buy locally (holding power that is).

Onto repairing the acutator. This is wear there Band Aids will come in handy.

I broke a couple of retaining tabs off, but there are no worries, the 2 "C" clips hold assembly to gether tightly.
Attachment 167722

Attachment 167723

Attachment 167724

Attachment 167725

Attachment 167726

The culprit:
Attachment 167727

Expoxied piece(s)
Attachment 167728

Reassmble......

I will report back on the repair side of this procedure if it does not last. IMO the expoxy is holding tight and may last a long time.