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Were you able to remove all of the original jammed business cards? where the leading edge of the "Fanfold" prints occurs, you will probably find something blocking the paper path. HP printers usually have a limit on the paper weight that the printer can handle when doing duplex (2 sided) printing. Check this against the weight of the cards you are printing.
Check carefully for any small scraps of paper caught in the paper path. Do a 1/2 way test, do a print job, listen for the paper to get just under the toner then quickly open the front of the printer (may take a few tries) see if the paper is folded there or if it's happening later that way. If it is folded before entering the fuser, you probably have a small piece of paper in the paper chute somewhere. If it's not and folds later, the fuser is probably worn badly.
For the black line check the toner cartridge roller (usually covered by a movable flap) to see if there is a black line on it. If not, then check the transfer belt (looks similar to a conveyor belt) for a line (probably not black in color, possibly white or grayish). If either of these parts have a line your best option is to replace that part. You could try cleaning VERY gently with a dry lint-free cloth but this may only clear up a little of the issue.
As for the fold, try running a paper path test, usually found under test, information, or diagnostic menu option on the printer itself. Try to find anything in the paper path that may catch the paper and cause it to fold.