Update:
Well it turns out it was not the door I was thinking of...it was another door on the opposite side of the building which I only replaced the lock on it...it still had the old thumb latch. But either way, it was still interesting. The lock on the exterior was functioning properly but if you locked it from the inside with the thumb latch it was really hard to unlock, you just had to muscle it.
So I took it apart and this is what I found...
http://i604.photobucket.com/albums/tt12 ... hoto-1.pnghttp://i604.photobucket.com/albums/tt12 ... /photo.pngOver the years the cam on the back had worn a huge groove out of it making it really hard to engage. Is this common? I cant tell you exactly how old the thumb latch was but it was not in the best shape. When you turned it, it just felt dirty...like someone threw a handful of sand in it; Even after I took it apart and cleaned it up a bit.
So put a new one on and it feels great. Not hard to turn at all, even when it engages. What do you think may have caused that to happen?