To append somewhat to what
starbolin noted and to more directly answer your questions (though I mostly aggree, and will partially re-iterate what
starbolin has already said:
1) You can manipulate the Perl stack anywhere you want, really; as long as you do it right.
2) I would aggree with
starbolin in that this design might not be the greatest. If you really want this module to be in XS, I would try to stick to a couple philosophies I follow (take it as a grain of salt, though): white your XS like you would write your Perl. In this case, you wouldn't want to write a PP module that would impicitly push onto a list to be returned so that another routine would be able to return it. Although it would work, it would be confusing and tough to debug and/or modify at a future date.
Everything considered, it is a little hard to say what the 'right' way to do it would be without a little more knowledge on the problem scope. Perhaps dropping some psudo code as a comment might better explain the module and what you are trying to do with it, therefore allowing for better analysis. Otherwise, I hope this addendum helps out a little and good luck with your module!