Really Weird CS5 problem?

I have an action which resizes and sharpens for printing.
I have used it all through CS4 without problem.
I saved it out of CS4 and loaded it into CS5.
It works fine in CS5.
A file produced by the action in CS5 is identical in all respects that I can see to a file produced by the action in CS4. Same pixel dims, same actual size, same profile, same ppi.
All exactly as expected.
BUT my Shiraz RIP server sees the CS5 file as a different size (4.17 x bigger linear) and rejects it as too big.
So there is something about the CS5 produced file which is different.
I have tried this on different images, always the same.
Perhaps I am doing something daft, but what?!
(Mac Pro 2006, 4x 2.66, 8 Gb RAM, CS5 running in 32 bit mode.
Shirax 6.4, Epson 4800)
Thanks for any help!

More investigation and I can re-state the problem:
1.Starting point a PSD file  which CS4 and CS5 report in Image Size as:
Width 4879 pixels
Height 6903 pixels
Width 16.263 inches
Height 23.01 inches
Resolution 300 pixels/inch
2."Save as" jpeg in CS4 and CS5 produces jpegs of same dimensions of course.
3. Submit the CS4 created jpeg to Shiraz and it is reported with same dimensions as 1.
4. Submit the CS5 created jpeg and it sees it as:
Width 4879 pixels
Height 6903 pixels
Width 67.764 inches
Height 95.875 inches
Resolution 72 pixels/inch
5. Save original PSD as a TIFF and submit to Shiraz and it sees it correctly as 300 ppi.
Something about CS5 jpegs is causing Shiraz to see the res as 72 ppi.
I have tried all different jpeg save options.
Hope this restatement may trigger some other ideas.

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