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those have a 2 latch system, sounds like the second latch that engages during the spin cycle never quite completed the safety lock , you could try and jumper the latch to see if that would release it, But it seems the secondary latch wasn't working properly in the first place, even the heaviest loads shouldn't pop the door open,
I am an experienced techician and have tried all these solutions in the past sometimes at no avail. But replacing the tub which has a limited lifetime warranty along with hinge arms will solve the issue. This has such a margional clearance I can never see anything visible causing the door to pop open
I have the same problem and it appears that everyone else who has replaced the door seal runs in top this issue. This is a new seal design that is different from the original. This new seal is obviously poorly designed is placing too much pressure on the door causing it to either not close, or open mid cycle. I am presently duck taping the door closed when running the machine in the hope that the heat cycling the new seal will eventually cause it to deform and relieve the pressure. I see that other have attempted to help the process by increasing the release pressure on the latch. This will be the last Kitchenaid large appliance I purchase.
this is joyce
What I would do in this situation is fix the door lock first before I would do another load of clothes. you can go to Kenmore.com put in your model # and download your manual to your machine if you want to fix yourself
or you can call service tech out. I will help you find one in your area if you need.
check to see if you have bent door hinges first, do this by opening the door all the way down and see if it is level with the floor. if it goes past level then the hinges are bent. guess someone may have fell on the door or used it as a step. if so, then you can take a hand towel and roll it up, then put it at the bottom of the door and close the door gently to "bend" the hinges back into place. this will aloow the door to stay closed and should also take care of the "burn" marks on your clothes. i would guess the unit was overheating from the door not closing right allowing air to enter around the door. that will cause the unit to overheat and leave marks on your clothes.
I would say that based on your problem description that the lid /door switch has a loose or faulty contact .. If you open and close it a few times..it starts to spin and yet when you open it.. it doesn't always stop the spinning.. It is either the switch or the actuator that bumps that switch.. That is where I would begin diagnosing the problem... Hope that helps..