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I hate to say it, but I would take the door out. It's apparently leaking, causing the rotting. I don't see an easy way of trying to cut out the bad wood and replace it with the door in place. What kind of siding on the outside? If it's vinyl, it's easy enough to take off and reinstall. I do it every time I replace a door for a customer. Trick is to pay attention to sealing up the door, flashing , etc., so it doesn't happen again.
Mike Hawkins:smile:
 

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Most often when I see this happening it's because of two things, there's a stoop, deck, patio even with the threshold on the outside.
Huge building 101 building mistake and a sure way to get water into the home.
The second thing is improper flashing.
When I set a patio door I use a sill pan and flashing up the sides.
Home Depot now stocks sill pans.
http://jamsill.com/
 

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2nd on removing the door. Underlayment damage is not a problem. You can let it dry out and leave it. You must look at how the header carrying posts, and all materials under them (to the foundation) are doing. Vinyl siding has J channels that act as a trough that carries all the water it will hold and drains it into the inside of the vinyl covers. Modern builders use tape to create drainage board for this water.
 
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