Door handle latch rod too long

I'm totally loosing my mind over this. I put on new door handles and the latch rod is inexplicably about 1/2" too long. I can push it up to connect it but then the flapper at the handle is pushed away so the button can't reach it. I took it apart again and used the old hardware that connects to the spring/button.
I searched online and somebody had the exact problem 10 years ago but never bothered to follow up if they resolved it.
I can remove the rod and shorten it but there has to be a more logical solution. The rod is NOT adjustable, no threads just a 90 on both ends.
The only thing that could adjust is where you connect to the latch but it doesn't seem to budge downward, the direction it needs to go.

Well I removed the rod, cut 1/2" out of it and welded it back together. Works perfectly but why did this happen??????
I hate threads that don't get resolved. I made it work but it defies logic

I finally got the missing rod clip for the other side. Same deal, door handle rod 1/2" too long. Cut it, welded it, works perfect.
As much as I'm happy that it's all good I wish I knew how this is possible?