Urgent!! Problems muxing .m2v files and audio!! MPEG Streamclip/Compressor

Hello!
I am under an urgent deadline to upload a short 6 min documentary clip for a client to review for screening this week. The footage was shot in 1080/60i HDV.
Usually, I find the best quality and fastest way to do this is to export directly from my FCP sequence using the '150 min Best Quality' DVD settings in compressor to get an .m2v video file and .ac3 audio file. Then I open the .m2v files in MPEG Streamclip which links it with my .ac3 file, then do 'Export MPEG with MP-2 audio". This gives me a single, muxed file that I can then upload to YouTube or Vimeo.
However, with this project, when I open up my .m2v file in MPEG Streamclip, it's recognizing the .ac3 file and I can see the info for it in the MPEG Streamclip window, but when I play the file in MPEG Streamclip or mux it, I don't hear any audio. Furthermore, after about 5 seconds into the clip, the playhead will continue moving, but the video will freeze, then maybe pick up again later. The .m2v video will play back smoothly in VLC player or Quicktime player, but not in MPEG Streamclip.
I've tried exporting different little sections of the timeline to see if maybe I had some corrupted footage or whatnot. I even exported a small clip from an older HDV project to test. But no matter where I export from, I am running into the same problem. I can bring the .m2v file and .ac3 file into DVD Studio Pro and burn a DVD with no problem, but I can't mux them. If I build the DVD file in DVD SP and try to open the .VOB file with MPEG Streamclip, I get the same problem. I even tried using a different software to mux (ffmpegX) but to no avail. When I try with ffmpegX, it either tells me I'm dropping frames, or if it works and it muxes it, when I open the MPEG file, it'll stutter at about 5 seconds in as well and I can't hear any audio, even though there is supposed to be audio in the muxed file.
I think I might have updated my Quicktime a few days ago with the system update, and maybe updated a few other things, so I don't know if this has any bearing on the problems I'm running into. But I was able just a few days ago to export HDV 1080/60i using this workflow without any problems.
I realize I have other export options, but this always seems to me to be the best quality and fastest way of doing it vs. encoding an H.264 which, on my machine is RIDICULOUSLY slow...I need to be uploading multiple versions of the cut to the client, and really need help! Thanks so much in advance!
J

what you want is an m2v program file. Export a reference copy from FCP (uncheck Make Movie Self Contained") That's very fast. Bring it into Compressor. In the settings panel find the MPEG-2 settings folder. Select Program Stream. Adjust to your liking and run. The audio and video will already be "muxed" when it's done and using compressor 3 you can set it to upload to YouTube, Mobile or similar sites.

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