FYI post only - just following up to update and close the thread and
thank everyone for their suggestions.

It was a PTF problem, but it appeared that at one point it was broken,
then fixed, then broken again and fixed again.

All the customers who had trouble with their laser printers (it was a
font size, line spacing _and_ top margin positioning problem) were on
V5R4. I ran DSPPTF to an outfile and looked at the printing related
ptfs of all three problem customers and compared them to 3 customers
that didn't have any problems, including our test box.

When I sorted each client's listing by PTF number, the levels each box
was on went something like this:

client 1 - worked fine: few of the listed PTFs installed.
client 2 - didn't work. a few more of the listed PTFs installed.
client 3 - worked fine, a few more installed.
client 4 - didn't work, a few more installed.
our box - worked fine, even more installed.
client 5 - worked fine, completely up to date.

This was clearly one of those things that you would never notice
unless you printed laser output to pre-printed form sheets or on top
of overlays as tight and as intricate as a W2

One of the clients had just moved from pin-feed W2s to overlays this
year, and none of the bad ones used lasers that way on a daily basis.

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