Okay so we have our baby working almost. Here's the problem.
What doesn't work.
Wrinkles 11 x 17 prints on thinner paper but letter size is perfect.
Only happens 40% of the time if paper setting card stock. (Using 28lbs paper)
**Always happens when paper is set to 20lbs - 28 lbs it and printing double sided.
Happens from every tray and bypass. (it's consistent.)
8.5 x 11 paper is perfect no matter what stock or setting is used.
What we've done.
Completely rebuilt and cleaned the entire duplex uni.
Replaced gears on fuser assembly.
Any suggestions? Thanks everyone.