On the passenger door of my Bronco with electric locks, the actuator popped out of its clip. We put it back where it mounts and secured it in place, but now we have to hit "unlock" 3-4 times to get it to unlock. It also takes a bit more effort to unlock by pulling the handle from the inside, and it's near impossible to unlock it with a key. Any thoughts/suggestions?

 

This might be a similar issues with our 1994 Pontiac Grand Am door locks.

It seems the previous owner might have tried to fix the driver side window motor problem but was not successful and it ended up messing up the power door lock actuator/handle.

Using the power button to lock/unlock the door locks is very difficult because the actuator is somewhat catching the sides and preventing it from moving properly in lock or unlock mode. It takes a couple of unlock button to sucessfully unlock the door. Pulling the actuator handle is somewhat restricted and need a little bit more force to unlock it. Using the key outside is also difficult and it seems like the key is fixing to bend just to open it.

I've removed the door panel and reconnected the door lock wiring harness and tried to operate it without the door panels and it worked smoothly without any problem.

I realized that the metal rod that moves horizontally along the actuator is a little bent and so when it is moving then it is catching part of the door panel and the actuator is also catching a part of the door panel.

I was able to play with it and got it straight somewhat and now it is not catching any part of the door panel. Now the power door lock switch works fine with just one touch of the button and it's easy to unlock or lock from the outside with a key.

 

IF, this is a 92 Bronco, and if Ford uses the same latch for power locks and regular locks, maybe I can help. I had the same problem on my 1992 F150;I couldn't unlock the door with the key, I couldn't pull the button up from the inside, and the inside door handle wouldn't open the lock.
In fact, the latch assy.from my pass side door is sitting on the garage floor right now.
It is probably a two part problem; Number one..rust. I hadn't been regulary lubing my locks. The driver side survived, probably because I use it everyday. Try spraying a rust buster in there. You can get it from the outside. Do not spray anything into the key hole, spray it where the latch is on the edge of the door.Let it soak a few minutes and it'll probably feel better.
Number two problem, crappy design or just soft metal. I have determined my lock couldn't be moved because the end of the actuator rod was rubbing against another part in the latch. The latch assy. is basically L-shaped. The main body of the latch bolts to the edge of the door with three phillips head screws. From that main body there is a flange that comes off the latch at a 90 degree angle and is parallel with the whole door itself. The flange holds the cable that comes from the door handle. I believe that this flange can be moved slowly over time by either, people pulling too hard and fast on the handle, or by people slamming the door.

If you can get the door panel off and get to this flange, I would suggest pulling it(Bending it) back towards the vehicle or towards you if working from inside the truck. It is very soft metal and there is space around it to move. The idea is to allow the end of the actuator rod to move freely up and down. If the flange is less than 90 degrees angle from the main body of the latch, then the actuator will rub against the flange.I suppose the flange could be set at a 95 dgree angle to the main body. I wish I could show you how to fix this sucker, because my explaiantion is lousy.

 

Thanks; I'll have to look into that. I just get so sick of working on it because it's way down in the door and there's no light or visibility..