Had the same problem earlier this summer. Inserted the tip of a knife between the door & frame & wiggled the catch just enough to operate the handle and open the door. We were starting to consider using the emergency exit, but fortunately didn't have to.
I removed, disassembled, lubed, & re-assembled the latch mechanism like you did - no change. Very odd...
I noticed that if I pulled the door in a little (or pushed it out, can't remember which), before operating the latch, it worked normally. The plastic surface of the catch was *ahem* catching on the metal edge of the striker plate & getting stuck. We've only had it happen once though - perhaps twisting of the door frame caused by leveling/jacking/etc at that site moved the catch/striker out of ideal alignment.
We've also had random occurrences of the outside door lock not unlocking. We tried flipping the keys, tried both keys, nothing. Then, after an appropriate amount of cursing & threatening, it randomly went back to working normally again. We've been using just the deadbolt as we really don't want to be locked out!
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