Based on what I experienced last year, once the IRS has rejected the return 5 times, that's it. You flat out can not e-file no matter what. Even if you get the info correct on the 6th attempt, it will still reject it. So you have no choice but to print, sign and mail it to the IRS.
Now I can't find anything on the IRS website about this. But I do know for an absolute fact (because I personally saw it) that after the 5th attempt, the reject reason was something like "to many attempts" with further wording to indicate the tax return flat out could not be e-filed, and "that" was "that".
