Door does not open when the customer pulls the exterior handle
▲ –80% customer claims after the interim action; case fully closed with the permanent fix.
Root cause: the lever spring cracks after 35–38k cycles, due to the elastic deformation of the paddle. A design issue was confirmed and a supplier process issue ruled out.
Fix: an additional spring as interim action, then a spring redesign (calculation, CAD, FEM) as permanent action.















