Here's how it's currently operating.
9 times out of 10, when I pull the outside handle the door does not open and I can see the lock tab move slightly downward. Not to the lock position but just a slight shift downward.
I can put the key into the lock, turn it to the right, pull the door handle, the door pops right open, I remove the key and roll on.
I have been looking at the diagram in the manual and I'm planning on taking the door apart again soon to replace the window regulator and should try to fix handle operation at the same time.

This also happens when I use the key fob.
I would push the button on the fob, all doors would unlock but the drivers lock switch wouldn't quite go as high as it should. As a result of the limited travel distance I would have to key the lock before opening the door.

Anyone experience this? I'm going to crack into it as soon as I locate a new drivers window regulator.

That being said, I also need a source for a regulator. I've seen all the usual stuff. Roverparts has one for $120, ebay has a bunch between $50 and $100, I actually saw a pair, front drivers side and passengers side for $75 with free shipping. It's a tempting price. If anyone has thoughts to share about a source let me know!

Cheers guys!

 

If you need just rollers there is a ten dollar fix for that.

 

Go over to discoweb.org -- and read their tech section, they have a write up on adjusting the door handle.

 

I wish. One side is bent up pretty bad (and a failed roller, of course) and the other has a damaged gear tooth. If you let it go all the way down it slips off and drops into the door.

Sweet, thanks! I just checked it out. That's a sweet website. Not sure how I haven't seen it before.

 

It doesn't seem like it's a handle adjustment issue unless I'm missing something. I think it's the actuator, and here's why. Thoughts?

The door will not pop open unless I am lifting up on the lock from inside or holding the key in the clockwise/unlock position. I've been looking at actuator operation and it almost seems like it's not sucking in enough when I turn the key or use the fob.
If I sit inside it, close the door and pull the inside handle to open it I can feel something in the linkage slip and also see slight movement in the lock handle.
If I lift up on the lock OR push the actuator 'plunger' all the way in, I can pop open the door.
My question is;
When you unlock the door, either by the fob or the key, where does this actuator come to rest? I feel it should rest, when unlocked, as far into the actuator as possible. However, this is not what I'm seeing.
This photo shows the actuators resting place when I use the fob. This position will not allow the door to open when the handle is operated with out lifting the lock or turning the key.


This photo shows the actuator plunger after I pushed it into the unit which allowed the door to open.



Is this an actuator issue? Or maybe a linkage issue? I don't think it's handle adjustment as the doors open fine when the plunger is pushed in, upward force (lifting) is applied to the lock, or the key is turned to the unlocked (clockwise) position.
Thanks

 

Can you unhook the actuator and then see what happens?
Have you tried lubing the actuator?
Mine would not unlock with the fob, lubed actuator with silicone spray, that was 4 years ago and it still works.

 

Disconnected the actuator, got in, shut the door and still had to lift up on the lock or pull forward on the connecting rod that goes to the actuator to get it to pop open.
Seems like a lock linkage issue for sure.
Would adjusting the door handles even affect how the lock linkage operates? It doesn't seem like it would.

I did lube the actuator. Operation seems smoother but I don't think it was the cause of the issue.
260k miles on this pig, I wonder if the lock mechanism itself needs to be replaced.

 

It very well could be the lock is bad.
Miles has nothing to do with it.
Locks don't wear going down the road.

 

Right, you know what I meant, not mileage but the usage that goes along with with it.
I'm not sure which part is at fault. I feel like that actuator slide / plunger should pull into the unit further. When it goes all the way in, by my hand pushing it, everything works fine.
At least I got the window fixed today. I'll shelf this lock problem for today. Thanks for your thoughts.

 

Todd - what did you ever find out about the lock? I'm having the exact same issue on my 95 and it's a little annoying. I chalk it up as one of the idiosyncratic things about the vehicle, but would like to get it fixed.