> With one document, though, the automated process stops with a "save changes?" prompt from WORD. It would appear to be a difference with the WORD docs since most of the docs run through fine. I can't figure out what is. Any ideas?

Any chance that one document is of merge type other than Form Letter? (such as labels, envelopes, or cataog/publication merge document type).

If so, I encountered similar behavior in my vertical market app when users run the canned merge documents that ship with the app with OfficeXP or latter. My 'canned documents' were setup a good while back in Office2000, and best I could figure was there's been some enhancements in mail merge functionality in newer versions of WORD that must make something different under the hood when using merge type of than form letter (the form letters i ship gave me no problem, just the labels/envelopes/publications and problem went away once the canned document was saved in WORD).

For my situation tho it wasn't a big batch run of multiple merge document like your situation, so I was able to just document the difference in the help file. But perhaps you can code a programtically save after the merge document is first opened to smooth out the wrinkle? HTH