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Sounds like the return lever arm is not putting enough pressure on the return clutch, or the clutch is slipping. The exp key uses the same clutch but the pressure comes from your finger. Theres no way you can fix this yourself. Get an IBM mechanic.
It sounds like a possible tab knockoff problem. This could be a small spring loose or broken in the escapement portion of the machine or the final knockoff in the tab unit out of alignment. You can try setting a tab before the end of the carriage by holding the carrier in place and using your other hand to press Tab Set, but the alignment may be just far enough off to keep you from actually setting the tab. One other thing that sometimes will cause the problem is the pitch setting lever is between the two pitches. Make sure your pitch setting lever is seated in its home position.
The margin release mech. is probably gummy and allowing returns to go past the margin. If thi is a dual pitch machine see if the pitch selector lever will move easily. If not use some WD40 on the margin rack.
If it returns with the express key the latching mech. on the rt. side is probably gummy. Take off the case, get some WD40 and spray the mechinism that latches the ret on the rt. side below the platen.
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