Exporting PDF files from SSRS 2012 - "There was an error opening this document. The file is damaged and could not be repaired"

Good day
I have the situation where we are exporting PDF files from reporting services in our website. 
When dividing the data into sections, the report exports perfectly, but when exporting the entire set and trying to open the file, we get the following error in Adobe Reader:
"There was an error opening this document.  The file is damaged and could not be repaired"
We tried to repair the file, no luck.  We tried to use different PDF readers, no luck
We then checked the file sizes.  When exporting the subsections, each section exports a file of about 2mb. 
When exporting the entire set, the file is about 1.3mb. 
Adding all the sections together gives me a rough estimate of 40mb.
Exporting to TIFF works beautifully and returns a file of 41.5mb. Word and Excel formats also work well, only issue there is the page numbering and formatting.
 The problem we have is the clients are adamant about having it in PDF format.
Any advice please?

This was one of the temporary suggestions I gave the client...
Unfortunately they do not like this as the page numbering and formatting in Word does not appear right.  We are talking about over 1300 pages.  I can't expect them to change the formatting with each export.  Additionally,  the data is
constantly changing and each client has their own data.  The clients export the reports randomly.  I therefore can't post the reports back onto the server.
Thanks for the speedy response though

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