I had this exact same problem on my 91 Silhouette. Every time someone would open the door with the interior handle on the passenger side it would cause the rod for the exterior handle to pop out of the door latch assembly. This rendered the exterior door handle useless. What had happened was that the door latch assembly had gotten so old that it 'over traveled' whenever someone pulled on the interior door handle. I fixed it by replacing the exterior door handle connecting rod with one I made myself. The rod that was in the car was too short, due to the over travel problem. So, I looked around the garage and found a metal rod that was long enough and stiff enough to work (it was a tie down stake for a child's soccer net, about 8 inches long and just the right width). I put it in a bench vise, bent it so there would be a 'notch' for the door assembly hole to engage and put it in. (I also cut off the end of a plastic drywall screw anchor and slipped it on the rod so the connection would be snug). I put this in the door about a year ago and haven't had a problem since. (Note: be careful of placement, because the makeshift rod can catch on the door lock cylinder connecting rod and interfere with locking the door. A few 'adjustments' with a pair of pliers corrected that minor problem for me.) Good luck!
Tuesday, October 20th, 2009 AT 7:17 PM