Missing TOC Book in Merged WebHelp

It's late on a Friday, and I'm brain dead. I am using a merged WebHelp structure (based on Peter Grainge's model with parent project only having one topic and using redirect to first child project) for my company's disaster recovery plan (separate department plans plus a master company plan). I recently added a new department plan. When I generate the merged help, the new department plan (Marketing) appears in the TOC but another one that should be there (Underwriting) is not showing up. Does this have to do with the length of the TOC? Seems like I recall having a problem with long TOC's before (in another job and project) but not sure if that's the issue or not.
Any guidance on where to troubleshoot would be appreciated. Thanks!

Unfortunately, I do have the same problem in Firefox. Just to clarify, I'm not viewing the merged plan in SharePoint; I am generating and viewing it locally on my C: drive. Copying to SharePoint is the last thing I do, so I haven't even gotten to that point yet, and when I do it, I delete all files on the server and copy all files again to it.
I tried regenerating AND publishing all of the plans to my C: drive (separate locations with same folder structure). I can either get the Marketing plan to show up or the Underwriting plan but not both at the same time.
Here is screen shot of the parent file TOC. They are all there. What am I missing? Have you encountered this issue before on the forum? I tried searching but couldn't find a situation that exactly matched mine. The Marketing plan only has 18 topics in it with 6 folders in the project file. The Underwriting plan has 33 topics in it with 6 folders in project file.
However, the IT plan, which comes before those two, has 226 topics and 7 folders, some of which have multiple levels of sub-folders going 3 or 4 levels down. I can send you screen shots of the structure, if you like. It's the most complicated one of the bunch. I've got to get this resolved as I am supposed to publish 1Q updates this week. And of course, I can't merge any additional department plans until I can determine where the problem lies.
Thanks in advance for your help!

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