Strange layers issue when printing

Hi Guys,
I am having a strange issue which is probably easy to fix however I am not a heavy adobe user and dont know where to start.
This is the rough process to explain my point but a summary is - when printing PDF files they do not appear as they do on screen.
A picture/document is created in Adobe Illustrator, an outline PDF is then created and saved
I can open the outline PDF successfully, in newer versions of PDF Reader (v8+) the PDF displays on screen correctly. In older versions the PDF is missing lines or various things.
If I print this PDF all these lines etc still missing. I know this sounds vague but I will try and explain.
An example is this - the document is a black box with a silver smaller box on top in the centre. On the screen it shows correctly. When I print, the black box is printed with no silver box.
I have just discovered that the silver box is actually printed however its printed in the background so I think its got to do with layers? If I make the black box to be white, and then print I can see my silver box, so its clear it has been printed in the wrong order.
Oh another thing I have found is the default format for saving PDF files is v1.5 if I choose an older version, the layers are printed correctly
I have both Adobe reader installed on Mac's and PC and the issue happens on both
Surely all the printers I have can't be all in-compatible
Printers:
Kyocera KM-4050
Kyocera FSC5200
Canon MX850
Lanier MP2500
Lanier MP2800

This is not a scanning resolution factor and I have been scanning this way for years. These scans are not photos but documents. This problem just started. And as I said before, the problem also occurs when doing a save as from Illustrator, as well as supplied files from clients, so the scanning process has nothing to do with it. I just can't get them to print right.

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[url=http://s1286.beta.photobucket.com/user/em0te-apparel/library/AI%20Print%20Issue]PICTURES[/url]

I, too am having the same issue printing from AI CS5. I have edited images in PS CS5 and there is a transparent background. I then placed (File>Place) the PSD files into AI and everything looks good on screen. However, I'm also getting a strange box that appears around my images—though the box itself isn't a solid opaque—it looks more like there's a overprint or screen and so it just shifts the colors behind it. I've tried saving the images as transparent PNGs with the same result. I've also tried playing with my transparency settings in the print dialogue to no avail.
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