Make sure the outter rubber seals are not causing the problem. When I installed mine a couple of weeks back, the seals were causing the handle from returning flush to the door. I made a few adjustments to the rubber pieces and left it alone for the day and the handle returns to the original position now.

BMW does update their parts quite a bit. The parts are expensive but they're great quality.

As for removing door panel, don't forget about the huge plastic black clip on backside of door panel. Usually you have to pull up and out with some force to release it, or you can pry bottom of door panel away from door and squeeze the metal tabs on metal door frame clip using a long 90 degree pick. br careful not to break the ambient light connector

still waiting for the part to arrive grrrrrrr

ok got it and its done, took me just on an hour, although i have to say many thanks to all those who have done this before and have posted your experiences and pics, without that this is not an easy task. plus i have already had a dry run at door trim removal.

i got an after market part, made in taiwan, am i happy with the results ... yes-ish

as others have posted while it works and looks a quality product, it doesnt seem to want to retract the door handle fully, i mucked around with the seal and sprayed heaps of wd40 around it, but no real improvement, so i hope it settles in.

the company i bought it from offers a 12 month warranty, so some consolation.

would i do it again yep to easy (now hehe) but i think next time i would pay the extra and get genuine.

still with the help from this site ive turned a $500 dollar job into a $145 so im happy.

AND i can open my door

So my demons won and I rebought the damn carrier and guess what...? It works JUST LIKE THE ORIGINAL. To anyone about to replace the door carrier, spend the extra skins and go OEM.

my new door handle carrier has settled down now and works perfectly, i,m in two minds about oem and aftermarket,
oem is obviously more expensive than aftermarket, and at first i was a little concerned when after fitting it, it felt a little sticky and wouldn't return smoothly to its rest position

but now as its turns out i,ll see how this one performs and if it breaks again or another door breaks, i,ll make my decision on how this original repair is travelling/how long it lasted