Did Sai Baba ever say he would return in a physical form after he left his body?

Yes, according to the teachings in Chapter 43, Sai Baba did provide this assurance to his followers before his passing. The text explicitly states, "'As an eight-year-old child, I will appear again.' Maharaj had told the devotees this before he left." This promise is presented as the word of a saint and is not to be taken lightly. To reinforce this idea, the text draws a parallel to the Krishna avatar appearing before Devaki. This assurance provided the devotees with full confidence that he would return, transforming their grief into hopeful anticipation for his reappearance.