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The only shells I could get to potentially hang were some cheap handloaded target loads I picked up when my son was qualifying for his SG merit badge. They vary in length, but they are between 2-3/16" and 2-5/16" all of my other factory shells are over 2-1/2" with most about 2-5/8". Since the Boy Scout regulations, only allow one shell loaded at a time, there was never an issue, I will donate the rest of these to the Boy Scouts and be sure to check any future loads I buy.

The Annoyed Man wrote:I have a 590 and I keep those Hornady Critical Defense 2-3/4" shells in it. I have cycled the shells through the action several times (unloading for cleaning), and I've never had the malfunction happen. But perhaps I'm doing it with enough authority to prevent it.

I have fired countless shells through my Mossberg 500, used it hunting with both 2-3/4" shells and 3", for over 10 years, and I have never experienced the malfunction mentioned. After reading through this thread, I attempted to replicate the failure, slow racking, racking at different angles, even upside down, and turning the gun mid stroke, with no failures. I went through all of the various rounds I had available, birdshot, target loads, buck and even slugs, no issues. I was able to reach in and manipulate a shell inside the chamber to make it wedge against the elevator tab, but I couldn't make it happen otherwise. I too have never seen anything regarding this issue. I agree if this is a common malfunction, Mossberg should look into extending the elevator tab to prevent it. I also wonder if it could be a magazine spring issue, which prevents the shells from "bouncing" back enough to clear the elevator tab. I will have to do more research and experimenting. (like I need an excuse to go shooting)

Thanks for the info Flintknapper.