Dana -

I can't put out a version of our software with the version 9 report engine turned on without everyone getting it, so no I can't test it on other machines.

I don't want to get too critical of your development environment because you obviously have very real constraints to work within.

But do you ever test releases on machines other than your development machine?
Can you test without rolling it out to users?

Also, SET REPORTBEHAVIOR 80 | 90 could easily be a CONFIG.FPW setting that you should be able to tweak on a per-user basis. If you have CONFIG.FPW built-in to you EXE you could excluded it and deliver it alongside the EXE... I'll assume you know this and you can't do it because of some reason that you haven't explained.

Is it not possible to create a cut-down, independent EXE that demonstrates the problem? I'd be glad to run such a test on my network in my office. Whatever results I experienced, we'd be able to move forward on isolating the problem.

It could be that you just don't have the resources to put into this exploration and research, but that would be a shame because Microsoft can't do this for you, not without a "repro" that they can run on their own test machines.

- Colin