Ok.. Never had a mechanical fuel pump for this 426 Hemi, and now I'm trying to install an original Carter mechanical fuel pump to the engine, and it WILL NOT sit flush. I went as far as removing the pushrod, measuring it.. and yes, it's 3.25 inches long. I lubed it up, installed it, and with my finger pushing the pushrod against the cam, I had my beautiful wife manually turn over the engine while feeling for movement of the pushrod... There again, it was normal. One more thing I did was when the pushrod was receded into the block while the engine was being turned over, I then tried to install the pump, and at that time, it fit perfectly.... but only when at that position. Turned the motor until the rod was sticking out at it's furthest point, and, and no way was that pump gonna fit. WTF ?

Any suggestions ?

It will stick out when the push rod does. If the pump was attached this is when it would be compressing the pump. Find where the rod is in and install it

Your probably just feeling the spring pressure from the pump. Do as stated above.

Before I do that, I would like a little clarification first....

The spring pressure that I feel is just a up/down of the lever with a little bit of spring resistance. It only travels about 3/8 of an inch. I cannot move the lever any further than that while I have the pump held down, and I put alot of my own force on that lever. It goes no further... I can't imagine spring tension inside of a fuel pump that I wouldn't be able to overcome on my own... That's one hefty spring in that little aluminum housing.

If you happen to have a fuel pump lying around, try it and let me know if you get another 1/4 inch of movement out of it..

I appreciate your help, but I just wanna be sure so I don't break anything internally if I don't have too.

Those springs are stout, meant to keep the pushrod against the cam at and above 5000 ROM. Put the pump in a vise and push the lever as hard as you can, it will compress more than you think I would put it in the motor with the pushrod on the heel(in all the way ) of the cam and try it. Why are you trying to install against the spring

It is not going to sit flush when the rod is on the nose of the eccentric on the cam .

Did you try tightening the bolts down ?

Even on the back side of the lobe there will likely be some pressure keeping it from sitting flush. Maybe roll the motor over and see if it gets worse/better to make installing it easier?