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I can not imagine any scenario where the plungers would come out a full inch.....worn out band material/ put together wrong etc.
The only thing I can think of is the drum being under sized. When you get it apart, check the drums for smoothness (no gouges or pitting) and for the proper diameter. The last guy may have turned the drums down on a lathe, and got them too far under sized. Here is an old thread on the drums http://www.6x6world.com/forums/trans...html#post46427
i went through and read for almost 3 hours the other night everything i could about the t-20 issues. I found 2 threads describing very similar issues that i seem to be having. so i made a video showing first hand. now another possibility is I also had a drunk truck driving girl standing next to me being loud and obnoxious to the point i finally had to send her down the road. only thing is the levers acted the same before and after I took it apart????http://youtu.be/axj2_2USU4c