[HoosierDaddy]

Hi Forest,
It appears to me that what you have should work...I have had mine apart . It can be very confusing to reassemble the locking cam . The spindle that it rotates on must be attached to the lock mechanism and "clocked" properly. The locking cam should rotate freely for 90 degrees so that the electric actuator can move it. The lock cylinder must then be able to move the locking cam to allow the key to unlock it. There is an insert in the lock cylinder that limits movement of the lock cylinder. If yours has been apart and the lock cylinder and the spindle are not in sync it may not allow positive movement of the locking cam when installed on the door. If you really need a longer locking cam I may have a couple. Post the lenght of yours and I will compare to mine and send you longer ones if I have them. You could also get them from a locksmith.
Also...I dont think longer cables are the answer. If everything else is in order I would try bending the "tab" that hits the locking cam (when locked) when you pull the handle thereby causing the tab to be closer to the locking cam.
Another thing....If you have abandoned the electric acutators the locking cam may be floating loose enough to rotate enough to allow the latch to open. If that is the case re-attache the actuators to keep the locking cam from moving freely or mechanically attach the cam to the spindle by using a lock washer under the screw or apply a dab of JB weld into the hole of the cam after you are sure you have it oriented properly.