Infamous door latch problem

[B.O.B.]

So my drivers door has a heck of the time opening from the outside. I tried to adjust the rod but then It bound up the mechanism and wouldn't lock. It seems that the part of the latch mechanism for outside could be worn enough that it won't push the mechanism far enough to open the door. What have you guys done to help this?

[Digger]

I am no expert on this matter. That being said, I will relay my observations from my truck.

There is a rod from the outside door button to the door latch mechanism, it has a bend in it for clearance. On my driver's door, the PO had welded a reinforcement "spine" in the area of the bend. That door opens with ease.

My passenger's door does not have this modification. What I observed was that the rod is not very rigid and as you push the outside button, the rod stretches the bend flat and is wasting valuable "throw". This means that if the rod is adjusted properly, it barely has enough throw to trip the latch. If you adjust the rod to make it easier to open the latch, it doesn't have enough return throw and it blocks the lock mechanism from resetting. (Moving to the unlocked position.) Lots of dry lube seems to help, but it is barely passable. Adding the reinforcement to the rod seems to do wonders for the operation of the latch.

[mickphatmac]

I 2nd everything Digger says 100%!

My experience was similar to yours. Follow the rod down that connects on top(from the thumb button) and disconnect the bottom part of that rod. There is an adjustable piece at the bottom of the rod that you will have to un-clip.

After you un-clip it, simply unscrew that little nut 3 full rotations and clip it back into place. I'll bet that fixes it. If not keep adjusting it down 2 screws at a time.

Mine was too short so I had to lengthen it. That sounds like what you have going on.
Good luck, hope you have skinny hands!

[B.O.B.]

I did clean everything and actually welded a bit more metal onto the back of the push button on top which actually pushes the rod down more. Works a ton better. I do see where the rod is starting to flex so I think I do need to go and weld another rod to it like the picture to give it some more bracing.

[sykanr0ng]

A trick to do while you are working on that is to put some small diameter rubber hose such as windshield wiper fluid hose on the rods to cut down on rattles.

[B.O.B.]

So I ended up welding another rod and it took any flex out of it. Works like a brand new door now. I would take pics and post but my welds look like something that came from my tissues.