After everything was reinstalled the outside door lever had such friction that it got stuck and prevented the door from opening. This usually also prevents the door from closing, but in my case it closed and then got stuck where the latch wouldn't open again. After tearing off the tailgate trim to get to the front door lock cylinder release screw, I was able to pull the outside handle lever back through the lock cylinder. Then, after inspection, shaving and oiling, the handle seems to break in properly, at least for the time being. Not the extra 2 hours of troubleshooting I was hoping for.
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