Might need to replace the door handle assembly or fix a linkage to it inside the door. There's a few threads here dealing with the same problem. Here's one that has an additional complication - couldn't open the door even from inside due to the child lock, but read through it . . . . http://www.subaruoutback.org/forums...6362-2005-outback-rear-passenger-door-mechanism-snapped-child-lock-engaged.html

 

Ok, so I tried this repair, and it didn't work:

The plastic repair just didn't hold, so I called around and got a new handle assembly.

I got home late and, trying to beat the cold and snow, I tried to rush the install. The handle installed just fine, and I just wanted to see how everything was fitting together and closed the door. The only problem is that I had removed the panel entirely and hadn't really reconnected the two cables to the anchors that lock/unlock the door and the one that actually releases the door.

Now neither the inside or outside handle open the door at all. Not sure what my next move is here, any ideas?

 

In post #19 of the linked thread, tastyorange reports being able to remove the door panel (card) with the door closed:

I was able to wrestle the door panel off the side with the child lock on. I was going to do it even if it meant damaging it. I had no choice. I was able to pull up the seat-cushion a bit to get leverage.

Not sure if there was any damage, other than the report of getting the black sticky stuff on other surfaces -- perhaps @tastyorange will respond.

If you can duplicate that, then that should provide access to the cables, either to the inner or outer door handle, at least enough to reopen the door and refit everything.

 

In post #19 of the linked thread, tastyorange reports being able to remove the door panel (card) with the door closed:



Not sure if there was any damage, other than the report of getting the black sticky stuff on other surfaces -- perhaps @tastyorange will respond.

If you can duplicate that, then that should provide access to the cables, either to the inner or outer door handle, at least enough to reopen the door and refit everything.

Ok, I brought it to where I bought the door handle just to see if they had any jedi tricks to pop it. They were stumped, other than to say we can bludgeon through it some way or other, but there might be some damage involved. They were super busy and couldn't schedule anything today, so I called around to another Subaru repair place. They said the same thing, but added "Why don't you take it to an autobody place? They deal with stuck and damaged cars all the time, and work for about half the hourly rate we charge."

I went into an autobody place, and they popped the rear seat out and had the door open in about 10 minutes. They also kindly mentioned that they see far worse dumbassery all the time, and not to feel too bad about it.

 

Wow... I fixed both those doors last year. I remember I had to bend the bottom seat cushion out of the way to pull the door panel off (after removing screws around armrest and lock). No, there was no lasting damage.
Don't want to do that again. The automotive touch up spray paint automotivetouchup.com worked perfectly. Looks exactly the same. Not cheap... but I didn't want black door handles.