PDF Maker Mail Merge error

I have Adobe Acrobat 9 Pro and Office 2007 operating on Windows XP SP3.
I have been using a Mail Merge word doc for sending out mulitple documents as attachments on emails.
I have tried to use the Merge to Adobe PDF option and the Mail Merge under the Adobe menu and get the same response on both options:
"Word experienced a serious problem with the 'acrobat pdfmaker office com addin' add-in. If you have seen this message multiple times, you should disable this add-in and check to see if an update is available. Do you want to disable this add-in?"
Any suggestions?

I'm sure glad someone seems to be having success finding work arounds...
I'm running Vista SP1, Office 2007 SP1, Acrobat Standard 8.1.5
I am trying to merge a newletter with an address list to PDF files which I then bulk send to print because I get labeled and stapled mail ready documents as output. The source merge file is DOC (2003 compatible) and I have tried saving it as a DOCx file as well.
Very mixed results with no rhyme or reason... frequently end with the ""Word experienced a serious problem with the 'acrobat pdfmaker office com addin' add-in..."
I find no weird characters to remove, running the review feature first didn't help...
This is not the first time I have used this process, nor the first time I've had this issue... Please Find Us Help!
Today's list has 106 names and addresses on it.
I try to merge the entire list... error, Serious prob... disable, No; Serious prob... disable, No; Word auto saved changes to NORMAL.DOT, Load it? No; Exit Word, Save Changes to DOC, NO; Reopen Merge DOC
I merge records 1 - 5 ... success, Exit Word, Reopen Merge DOC
I merge records 6 - 20 ... success, Exit Word, Reopen Merge DOC
I merge records 21 - 40 ... success, Exit Word, Reopen Merge DOC
I merge records 41 - 60 ... error, Serious prob... disable, No; Serious prob... disable, No; Word auto saved changes to NORMAL.DOT, Load it? No; Exit Word, Save Changes to DOC, NO; Reopen Merge DOC
I merge records 41 - 50 ... error, Serious prob... disable, No; Serious prob... disable, No; Word auto saved changes to NORMAL.DOT, Load it? No; Exit Word, Save Changes to DOC, NO; Reopen Merge DOC
I merge records 41 - 45 ... success, Exit Word, Reopen Merge DOC
I merge records 46 - 50 ... success (guess it's not something in the merge data)
- Realize that between each merge operation, I exit word and reload the document because I've never gotten a second attempt to go otherwise)
- I watch memory (always at least 50% of system available, stable use by WINWORD.EXE and Acrodist.exe during the operation), processor (busy, never pegged, combine WORD and Acrodist never more than aprox 55% of utilization), over 50G of disk available
I merge records 51 - 80 ... error, Serious prob... disable, No; Serious prob... disable, No; Word auto saved changes to NORMAL.DOT, Load it? No; Exit Word, Save Changes to DOC, NO; Reopen Merge DOC
I merge records 51 - 60 ... success, Exit Word, Reopen Merge DOC
I merge records 61 - 80 ... error, Serious prob... disable, No; Serious prob... disable, No; Word auto saved changes to NORMAL.DOT, Load it? No; Exit Word, Save Changes to DOC, NO; Reopen Merge DOC
I merge records 61 - 70 ... error, Serious prob... disable, No; Serious prob... disable, No; Word auto saved changes to NORMAL.DOT, Load it? No; Exit Word, Save Changes to DOC, NO; Reopen Merge DOC
I merge records 61 - 65 ... success, Exit Word, Reopen Merge DOC
I merge records 66 - 80 ... success, Exit Word, Reopen Merge DOC
I merge records 81 - 100 ... error, Serious prob... disable, No; Serious prob... disable, No; Word auto saved changes to NORMAL.DOT, Load it? No; Exit Word, Save Changes to DOC, NO; Reopen Merge DOC
I merge records 81 - 100 ... success (no exit / reopen)
I merge records 101 - 106 ... error, Serious prob... disable, No; Serious prob... disable, No; Word auto saved changes to NORMAL.DOT, Load it? No; Exit Word, Save Changes to DOC, NO; Reopen Merge DOC
I merge records 101 - 106 ... error, Serious prob... disable, No; Serious prob... disable, No; Word auto saved changes to NORMAL.DOT, Load it? No; Exit Word, Save Changes to DOC, NO; Reopen Merge DOC
I merge records 101 - 106 ... success, Exit Word, Reopen Merge DOC (think about drinking and using labels in the future)
delete all pages from merge doc except for mailing page, Save As test, Exit Work, Reopen TEST.DOC, retry stipped down document
I merge records ALL ... success, Exit Word
So is document size?

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This thread may have your answer:
http://forums.adobe.com/message/1924439
(Paul_Kuczmierczyk) writes:
6. Dec 18, 2008 10:09 AM in response to: (Ray_Whitfield)
Re: PDF Maker Mail Merge error
I've had this same problem with one word document and I think I figured out what is going on, at least in my case. I'm using Word 2003. I tried a test of one merge record, and it worked, but when I tried to complete the entire merge, it failed. After trying several times to no avail, I noticed that the first word in my document had the red spell check underline, even though the word was not spelled wrong. When I placed my mouse cursor in front of the first letter of the word, the font information said "ZWAdobeF" and the size was 1. After I deleted this and tried the merge to e-mail through the Adobe plugin, it worked flawlessly. After the merge was completed however, that font reappeared in front of the first word in my document.
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This thread may have your answer:
http://forums.adobe.com/message/1924439
(Paul_Kuczmierczyk) writes:
6. Dec 18, 2008 10:09 AM in response to: (Ray_Whitfield)
Re: PDF Maker Mail Merge error
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