Originally Posted by
surfandturf
You can get it to roll nicely but the issue is when it makes the turn in the track and tried to get into the opening it fights hard. You have to push hard to jam it in and then the handle is hard to drive the pin into the upper opening.
Maybe treat these two items as separate issues. First, remove the lower guide assy and with the door handle/latches open slide the door closed. If the upper roller arm is preventing the door from moving flush with the opening it maybe bent. The goal is to get the door in the opening flush to the airframe... even if you need remove the upper guide arm. But use caution and have help as if you let the door drop with only the center track connected you'll have more problems. Once you can get the door flush and latched, work your way back and see what part is causing the problem.
If you get the door flush, but the door handle will not latch easily then that should signal you have two separate problems. However, usually once we would get the door to seat flush in the opening the latch issue was no longer a problem. But if it is check to make sure there is no axial play with the handle shaft as if there is this is a sign the internal teflon spacers are missing and it can bind the latch linkage. As you mentioned these doors usually work great but when they don't they can be a pain. Good luck.