FYI, for anybody and everybody that has trouble with the door latch mechanism locking up and causing a “I can’t open my door “ situation I believe that I have found the root cause of the problem.
The o-rings in the push button are a contributing factor but not the root cause.
I spent hours with my door panels off trying to determine what was causing my problem. At some point I dug out an original handle that I had and started comparing it with the new handle. That’s when I noticed that the tang on the mechanism that rotates up and down when you push in on the push button is longer on the new handle than the one on the old handle. At that point I re-installed the new handle without booking it up to the latch and saw that the tang was rubbing the inside of the door skin and would sometimes hang up. This created a situation where the lock mechanism in the latch would hang up midway in its travel and not allow the latch to unlock.
I disassembled all my brand new handles, ground enough off of the tang to allow for some clearance between the tang and the inside of the door skin and solved the problem. Picture below.
Hope this helps someone.
Steve
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