The route solver will sum the length of all the features (and prorated length of the partial features at begining and end of the route) and return the sum. It cannot be any different than the length field that is being used in the evaluator. Are you absolutely sure that the evaluator in the network dataset is pointing to the same length fields? You can use the network identify tool (second icon from right on the NA toolbar) to inspect the values of individual edge elements. Check if the values being returned are same as the length field that you have. ALSO, do you have some scaled cost barriers or turn delays or junction impedances, etc that could add to the overall length of the path?
If everything is ok, then you have to use the Copy Traversed Source Features tool to generate the lines, junctions and turns that make up the route. If it all looks ok, then I suggest you contact tech support for them to look at your data.
Jay Sandhu