A B757-200 ON INITIAL CLB AT 7000 FT RETURNED TO THE FIELD DUE TO THE R FORWARD ENTRY DOOR UNLOCKED CAUSED BY INCORRECT JOB CARD ADJUSTMENT PROC.

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ON CLBOUT; FLT ATTENDANT RPTED THE R FORWARD ENTRY DOOR BECAME UNLOCKED; AND HE WAS UNABLE TO RELOCK IT. THIS WAS ACCOMPANIED BY COCKPIT INDICATIONS OF THE DOOR BEING UNLOCKED (EICAS MESSAGE AND OVERHEAD PANEL ANNUNCIATION). WE LEVELED AT 10000 FT MSL WHILE ACCOMPLISHING OUR FLT MANUAL PROC. WE CONTACTED OUR DISPATCHER AND MAINT COORDINATOR. BOTH AGREED WITH OUR RECOMMENDATION TO RETURN TO DFW. WE CHKED OUR WT AS WE BEGAN OUR DSCNT; AND IT WAS BELOW THE MAX LNDG WT. WE LANDED AND TAXIED BACK TO THE GATE UNEVENTFULLY. MAINT WAS GIVEN THE AIRPLANE FOR REPAIR; AND WE DEPARTED AGAIN APPROX 3 HRS LATER. UNFORTUNATELY; THE SAME SEQUENCE OF EVENTS REOCCURRED; AND WE AGAIN RETURNED TO DFW. THE FLT WAS THEN CANCELED. SUPPLEMENTAL INFO FROM ACN 444062: ARRIVED AT ACFT XYZ AND INSPECTED DOOR AND DETERMINED DOOR TO HAVE VERY LITTLE HANDLE FORCE; WHEN LATCHED. ADJUSTED AND OPS CHKED DOOR PER B757 MAINT MANUAL PROCS. ACFT WAS DISPATCHED TO SVC AND EXPERIENCED SAME PROB CAUSING SECOND AIR TURN BACK. IT WAS LATER DETERMINED THAT THE STOP PADS WERE OUT OF ADJUSTMENT. ACR CORRECTIVE ACTION IS TO INCLUDE STOP PAD ADJUSTMENT TO ITS ROUTINE INSPECTIONS ON LETTER CHKS; MID VISITS AND OVERHAULS.