Have you tried simply cleaning the pinch-rollers with Q-tips and Rubber Renew? Perhaps something on the rollers is sticking to the TDK formulation, like more TDK formulation.
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I was looking up some of the old blank cassette tape tests from the late 70's through early 90's and TDK always won in the type II and type IV(metal) category's,but i guess even if TDK does sound slightly better it means nothing if the tape is not going to last..Plus i think TDK got most of it's reputation in thank's to Nakamichi,i guess most folks thought if TDK is good enough to be recommended by Nak it must be the best,even though the Tandberg 3014 will blow away anything from Nakamichi,and guess what brand Tandberg recommends and adjusts it's decks too?you guessed it MAXELL..
You may have a problem with deformed cassette shells that may cause the tape to track incorrectly. I have encountered such with Maxell XL-2 of late. Brand new you could see the cassette halve is bowed. I have encountered similar with TDk from time to time though very rare. Try an experiment just for fun, and swap the Tdk tape reels into a Maxell shell and see what happens or vice versa. Almost certain a bad shell is causing this healthy appetite the sony has for TDks'. Hope this helps,sincerely,Vincent.