When you print the return, youve got he box checked for the Client Copy?

Yes, of course.  I have done that.  I also get an error that "client copy did not print"

If you hit the Print Preview button, do you see both the filing copy and the client copy in the window?

If you print to PDF, does the client copy get included?

When I hit print preview, I see both, but when I print, Client copy does not print nor does it show up on the pdf.

super weird. I only print the Filing copy for both the client and myself, so I dont have any experience with printing the client copy...the only other thing I can think to check would be in the Global Print Options >Control Which Forms Print you could Restore Default Settings, but that would screw up any custom form print settings you may have changed previously.