The return address appears if the merge is sent to a new document. That document's size, of course, matches that of your mailmerge main document (i.e. your nominated 8.75in x 5.75in envelope size).
Does it print if you print from that document? If not, are you sure you're using the right envelope size in Word? If your answer is yeas to both those questions, you may have a faulty/out-dated printer driver. In that case, go to the maker's website and download & install the latest printer driver for your printer & system.
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Cheers,
Paul Edstein
[Fmr MS MVP - Word]
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