I can imagine that Word is generating the emails far faster than the mail
program can handle them and it falls over as a result. I think that you
will probably need to execute the merge in batches.

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Hope this helps,
Doug Robbins - Word MVP
> We are attempting to send a mail merge e-mail to 12,000
> students and the merge is failing each time we attempt to
> send. We get the "would you like to send Microsoft this
> error report" but no further explanation. Any one aware
> of a limit on recipients?