A couple of months ago all four of doors were creaking so loud it was embarrassing, so I took the mechanism apart and regreased all the rollers.
All was fine until last week when the front passenger door started making a noise. The door wouldn't stay open and I soon found the trouble.
This is from the inside of the door:
This is from the door shut:
Picture of the drivers side:
I took everything apart and welded what was left of the metal to the bracket
Putting it all back was a nightmare as the metal had been folded inside the door.
Using many implements of destruction I managed to get it reasonably flat to take the assembly.
Using the point and hope method I mananged to weld the whole assembly back into the door.
I then had to replace the door link which I made easier by removing the roller and pin
Replacing
Now I don't have to run round the to passenger side just in time to stop my passengers trapping their legs as they get out!
Looks like it work hardened and formed a crack over the years. Either that or you have a very large regular passenger 
Nice repair bud 
