Evening all,
When I got my Z4 the door lock actuator went into deadlock and I couldn't open the door from inside or out (worked fine on the test drive!).
Thankfully colleague is an ex BMW tech and managed to get the door card off in its locked state and set about going at the lock with a dremel to try and remove the deadlock.
For reference this is what a new lock looks like


Getting more and more broken up!




New door lock was fitted and inside worked perfectly. What didn't was the outside door handle. We could only make it work by fitting the bowden tube in the wrong location and preload it. We replaced it with a new one but same problem.

That was it, time for a new carrier and bowden cable. Upon checking the new carrier against the old carrier, we noticed the middle tooth as much smaller than the new one

There was lots of polishing on the tooth and clearly work away over time. This has now been replaced and the door is working as expected.
So if you have a poorly working exterior door handle; replace the door carrier but check that tooth for signs of wear.
When I got my Z4 the door lock actuator went into deadlock and I couldn't open the door from inside or out (worked fine on the test drive!).
Thankfully colleague is an ex BMW tech and managed to get the door card off in its locked state and set about going at the lock with a dremel to try and remove the deadlock.
For reference this is what a new lock looks like


Getting more and more broken up!




New door lock was fitted and inside worked perfectly. What didn't was the outside door handle. We could only make it work by fitting the bowden tube in the wrong location and preload it. We replaced it with a new one but same problem.

That was it, time for a new carrier and bowden cable. Upon checking the new carrier against the old carrier, we noticed the middle tooth as much smaller than the new one

There was lots of polishing on the tooth and clearly work away over time. This has now been replaced and the door is working as expected.
So if you have a poorly working exterior door handle; replace the door carrier but check that tooth for signs of wear.