So I’ve been having a similar issue but if I could lay out all details to see if anyone has a tip
Three weeks ago I began replacing a drivers side door handle carrier. This is my third x5 and is always a recurring issue so I’m very comfortable now replacing them. Hadn’t put the door panel back on and went to go somewhere and my battery/alternator quit.
So then after a new alternator and battery I’m up and running again. Back to the door project!
Door was opening and closing fine with new carrier, door card still off and window switch attached. Locks working with key fob, and still do. I locked the door with fob and then No!! Cannot open door. Door stuck shut.
The door card is open so I can easily see carrier is attached with ball clip properly seated. It moves the levers and I’ve manually moved them in the manner of the slim Jim trick to see if it just isn’t getting far enough but it seems that part is working properly. The inside handle wire also seems to be working fine.
So I’m thinking all I have left to try is the 12v to the actuator? Is there any other manual flipping of the levers I can try being that the door card is open?