Comparing the supply to return line I would expect the return to have a higher line resistance based on the following.
I have an 8an pickup line from the tank to the pre pump filter, then once it's at the pump I have 6an line to the small filter and then FiTech unit. This should have very little restrictions. Now for the metal 3/8" existing line that I am using as a return it was an oem copy but larger diameter. Measuring it appears to be 3/8" outside diameter. Then with the various bends, turns, etc I can see how this line would have a different resistance rating than my supply. Due to the resistance difference that's why we were thinking it could be an issue. If the return pressure is low could I do a quick trial with standard fuel hose back to the tank and see if it make any difference or at least eliminates the return as the culprit? I hate to spend $105 on efi hose for the test and if it's not the issue. If it does fix it I would swap out thw line to efi rated right away.
I had the same issue with a full tank as well. The return fuel seems to be a pretty low pressure as when I turn the pump on it sounds like it it's just trickling out.