William
Thanks for the pointers. Still no joy.
* The problem only affects the approx. 12 new templates that form the basis of the new document being worked on.
* Existing older templates all behave as expected
* New templates can be saved as other formats with no issue
* File name is only accepted if < 8 chars from the problem templates.
* Other Office applications are unnaffected
* the solutions on the link do not help
* Changing the location of the templates (e.g. to local template folder) does not change the behaviour.
To reiterate the issue is with File > Save As > PDF and not with
File > Save & Send > Create PDF
Dan Kelly