my side door on my 01 transit will sometimes not open,but you can hear the door catch unlocking ,any ideas on how to fix

 

Bit of grease on the latches/runners maybe?

 

i have had this problem many times.

if its a w reg onwards new shape tranny as you can get the old shape up to a y reg,the mechanism comes off the inside of the side loader,take the door card off and try the handle,watch the mechanism working and you should be able to see if its popped out thus making the door not open properly.

 

I have had this too, it was the cable running inside the door.
They overstretch and need replacing mate,