'95 Bronco XLT. I took the door latch and rods out to replace the inside latch cable. Re-assembled it all as it came apart. Now I have a strange problem. The door opens, locks and unlocks just fine unless it is locked and you push the outside door handle button when it is locked. Then it will not unlock with the key, the inside lock **** or by pulling the inside door handle.

I don't know if it had this problem before because it was a wreck I bought to rebuild so I haven't really driven it yet, and the inner door cable was broken.

It seems simple enough just to not push the outside door button when the door is locked and I'll have no problems, but it will be my wife's driver and if she forgets and pushes the button when the door is locked I don't want to have to pull the door panel off to fix it.

The way I get it to release is : reach inside the door from the inside and push the lever on the latch assy. up then it will unlock and release. It's the lever that the outside door button pushes down, it's like it doesn't come back up all the way in this situation. Until I do this the inside lock **** will only come up halfway.

WTF???

The passenger's side door does not do this and I can't see any difference in how I have all the rods and latch installed.

I had thought it was a problem with the lock actuator so I removed it and there is no difference.

 

where did you get the parts?

 

The inside latch cable is a Dorman from Autozone and the inner handle is the same, the rest of the parts are original.

 

Lube the entire mechanism (including the door button) with a quality penetrating lube like tri-flow or aero-croil. Work the mechanism a bit to get it worked in and that may solve the problem.

 

Sounds to me like something inside is bent ever-so-slightly, or is not totally seated correctly when put back together.
I had an older Toyota that when the outside door handle was replaced, it worked fine, but the cable wasn't *EXACTLY* in the groove it was supposed to be in, and it kept pushing the window out of it's track - not instantly, but within a few days of re-seating it.
What you're describing sounds similar to me. Something is positioned "just so" whenever it's in the locked position that pushing the button causes it to hang on whatever piece is not *EXACTLY* where it's supposed to be. It could be off by as little as 1/16th and still cause a problem.
Or, it could be something completely different... LOL.