update:
today seemed warm enough to finish this off, when I posted the thread i got as far as taking the door panel off before my hands froze
anyway, popped the clip off and removed the barrel. It was pretty much bone dry, so oiled it to free it up then packed every crevice with grease and now it works fime

it's obviously worn as I can see it going out of true when releasing the deadlock, but it'll do for a few years I think.
However,
replacing the spring clip is almost certainly the most frustrating job I have EVER done on a car, and that includes chaning a cam belt on a 2l cortina without taking the radiator off.
I came -very- close to just cutting an access panel in the door with my grinder...
my tips for doing this:
1: gaffa tape the lock in place on the outside of the door
2: get a magnetic pickup tool
3: use mag tool to place clip
4: lever clip in so mag tool can be removed
5: use a drift to tap clip home.
step 3.5 is 'drop clip 1 million times into the door then swear a lot'
anyway, I'm a lot happier now
