Through some research, I have found the issue - a known MS bug. See the details:
MS Knowledgebase article Although we don't have to take the steps outlined in the article to experience the issue, at least is confirms for me that it is a known bug. The problem is in the way settings are saved within a document when you change from a PCL printer to a PS printer. Evidently there are settings that are incompatible between the two.
To solve the problem all you need to do is (assumes you are trying to print to printer A):
File > print
Change the printer from A to B, given that A and B have the same printer driver.
- All of our printers use the same driver, so that is not a problem. If all your printers do not have the same driver, then you will need to install printer A a second time (before starting this process), but give it a different name, B, for example.
Click on the close button.
You should see all of your page breaks disappear.
File > print
Change the printer back to A.
Click on the close button.
Print preview the document.
If is still isn't quite right, the scaling is probably set to 10%. Change it back to your desired settings.
All should be fine.
Something else I discovered while on this journey - if you set scaling to 1 by 1 page and have columns and rows set to repeat on each page, it really messes with the scaling. Once we took out the repeating elements, it was fine.
Here is why we are experiencing the issue:
For reasons I am sure I don't need to go into, we publish our data in PDFs using PDF995.
Because it uses PostScript and our IT dept forces the use of PCL drivers for our printers, we end up with the problem. What I don't understand is why we are just now experiencing the issue. We have been using PDF995 for about 2 years with no upgrades since first install. Probably related to a print server upgrade of some sort.
As usual, Eric was pointing me in the right direction. I just didn't make the connection with PDF995 because we have used it successfully for so long and I didn't see it as an "unusual" printer like a label or receipt printer. I'm sorry I doubted your suggestion, Eric. You are THE man.
I hope this post helps others avoid the stress and wasted document recreation efforts our department has experienced because of this bug.
Scott