Starter solenoid troubles

[J-440]

Before I call Powermaster I need some expert advice. I recently bought a new starter and for some reason, the gear is not popping out all the way and engaging the flywheel. I've tried a longer spring, some washers, and even different lengths of screws to make the solenoid shaft longer with no luck. I've got 12.5 volts at the battery and have benched tested this thing several times. It spins fine with lots of torque but just doesn't pop out all the way. Do I need a longer solenoid? Thanks.

[Bolt-Action]

When you bench tested the starter it functioned, correct?
Can you hear the gear striking the flywheel?
(Is this a 440/833? I'm assuming...)

[J-440]

Bolt, I bench tested it as well as had my wife turn the car over while I was underneath and watching. It pops out and spins fine, just not enough to make contact with the flywheel. This is for a 440/727(auto) combo.

[Bolt-Action]

Ok gotcha,
Are you hearing the starter gear strike the ring gear on your TC?

^Never mind I just saw your answer.

What's the part # on your starter?
What torque converter are you running?

Just an FYI for future use, you can pick-up a late 90's to early 2000's dodge magnum v8 starter (i use the Ram 2500) for real cheap, and they're a high torque starter stock, and they're smaller and lighter to boot.

[J-440]

It's the only starter for a Mopar that Powermaster makes. It's 160ft lbs for an 8.5 comp ratio. Also it's a 2200 rpm stall converter.