UPDATE: really wierd thing happened about 6 days ago...i saw a piec of plastic insulation inside the latch kit (i never took it apart, just looked at the normally exposed parts) i cut the piece and now the door is fine, although we haven't had any intense heat yet...
but the door is opening from both the inside and outdoor handle...and closes fine, my mechanic took a look while it was in for a master cylider, he said he couldn't find anything wrong with it. | 
