Yeah. I believe now after tearing into all these pumps you had the correct solution all along. Unless I had actually seen it on several pumps I would not have believed the plunger could stick like that. Now I know better. I should have listened to your years of experience here "Floridianson" ! The clearances on the plunger shaft are so tight it will create a "pop" when pulled out of it's bore. According to my machinist friend that means it was "hand honed" together. Just another reason to keep good fuel filters on the deuce. Any bit of garbage getting on the shaft will score it up and it will not seal properly and start to leak and lose pressure.