team doorhandle strikes yet again

[Mike Arman]

Team doorhandle got me!

86 5K

Unlocked car from driver's door, wife grabbed outside passenger door handle
before locking system had finished cycling, door didn't open, so she
squeezed harder, plastic rod end popped off the little ball.

Remove interior panel, pop plastic rod end back onto ball, (fix window
while I'm there - a drain hole was clogged, there was an inch of water in
the bottom of the door, the cable on the window mechanism is rusted -
replace with spare motor and cable assembly, lubricate everything),
re-assemble.

Three days later, I go to unlock only the passenger door, and am rewarded
by resistance to turning the key, and the rod end pops off again!
(sonofa*****!)

Now I know I'm going to have to change the rod end, and I have some spares.

My question is this - is there a position the lock/vacuum capsule/pushrod
cycle and assembly has to be pre-set to before it is assembled? ("Door
unlocked, capsule up, key in unlock position" or something like that?) or
is the old rod end just bad? (I'm thinking there is a set of conditions . .
.  )

There HAS to be a better way . . .

Best Regards,

Mike Arman