That is not wear and tear but looks to me like a defective piece of steel was used to make it. I think that a crack started at the edge of the hole that the locking button assembly mounts to, which then travelled upwards along the pressed corner. Once it reached the top, the whole bar would be vibrating and fatigue would have helped the next crack to travel downwards.

I'd go back and tell them that you are prepared to commission a Metallurgist to report on the failure, and that you'll be expecting to recover the cost from them.
 
Here are a couple of photos taken when it went into Landrover, customer services have said no to a replacement door, they offered to have it welded but their body shop have they won't offer any warranty on the repair as it needs a new door!!
that could be welded easily ,that area is very common on earlier models
 
How did you first notice it? My drivers door has had a rattle when it is slammed shut for about a year, haven't taken it apart yet to see what the problem is. Passenger door shuts easily without slamming, but the drivers door needs a light slam to overcome the door seals. Up to now I was thinking it is a loose wire rattling, but might be the same problem as yours.
It started the same as how you describe, i just noticed the door card wasnt holding on with the grub screws and the plastic thing round the button kept on moving and rising up. The electric window then packed up and when my partner took the door card off we saw the broken part, therefor it went into Landrover to have the window fixed which has lasted all of a week.
 
I have 2012 Puma doors on mine. Luckily not had this problem but will keep an eye open for it knowing it is a dodgy area!
 
Wow..... If there's no damage to the rest of the door then looks like faulty pressing/steel. That said looks v easily welded rather than whole door, so I'd go for that if it was me.....? The 'no warranty' is nonsense, this is fixing what was warranted as durable in the first place, but no need to argue the toss, just put it in writing you disagree but will bottom that out later if the door fails again in normal life expectancy. Looks like you got a fix anyway, good news. A
 
Do a bit of research on The Sale Of Goods Act. The retailer (not the manufacturer) can have a responsibility to a product for up to 6 years from date of sale. If it is reasonable for you to expect a door on a vehicle to last more than 4 years without falling apart, and the door has only seen reasonable use in that time, the retailer should repair or replace it for free. That's the law!

Bit out of date now MG - try the Consumer Rights Act....... ;-)
 

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