Display PDF in Browser - Item failed to convert, Outlook 2003 - PDF failed to create.

Hi Experts,
 
This is a bit of a pain I have to distribute
Adobe Acrobat Pro 8.1 to about 3000+ users and I am having a problem,
 
In Prefs in "Adobe Acrobat Pro 8.1"
 
When I tick then untick, "display in PDF Browser" from the Preferences, My Outlook will fail to convert to PDF. I get an "Item failed to convert" message and a log file. Also Word 2003 will not post a .PDF to an email.
 
If I restart "Outlook 2003" it will create a "pdf" when I click the icon the first time, the second time I click it will fail.
 
This is on Windows XP SP2, Offce 2003 SP2 and Adobe Reader 8.1 is installed.
 
Please help.
 
This is the log file
 
===================================================
 
Requested: 1,
Converted to PDF: 0,
Skipped [Already in PDF]: 0,
Skipped [PDFMaker failed to convert]: 1
 
Details of Email to PDF conversion:
Failed to Convert:
From: xxxxxxxxxxxx, Subject: FW: testing, Date: 8/08/2007, Status: Item failed to convert
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