I can't tell where your "Popup" and "Program" numbers are coming from,
but I can tell you that Word has several different ways of counting
characters, words, sentences, and paragraphs, and none of them agree.

- You can get the values from the Readability Statistics dialog that
appears at the end of a spelling/grammar check.

- You can look at the results of the Tools > Word Count dialog.

- You can take the .Count values of the various collections in the
object model.

This demo shows how to get those values, and running it against any
moderate-sized document will show how far out of whack the methods
are. Further, it shows that the ratios in the Readability Statistics
often don't match the values they're supposed to be calculated from.

Sub Discrepancies()
   Dim msg As String
   ActiveDocument.Repaginate
   
   msg = "From ToolsWordCount -----------"
   msg = msg & vbCr & "Characters (with spaces):" & vbTab & _
       Dialogs(wdDialogToolsWordCount) _
           .CharactersIncludingSpaces
   msg = msg & vbCr & "Characters (no spaces):" & vbTab & _
       Dialogs(wdDialogToolsWordCount) _
           .Characters
   msg = msg & vbCr & "Words:" & vbTab & vbTab & vbTab & _
       Dialogs(wdDialogToolsWordCount).Words
   msg = msg & vbCr & "Paragraphs:" & vbTab & vbTab & _
       Dialogs(wdDialogToolsWordCount).Paragraphs
   msg = msg & vbCr & "Sentences:" & vbTab & vbTab & "n/a"
   
   msg = msg & vbCr & vbCr & _
       "From Readability Stats------------"
   msg = msg & vbCr & "Characters:" & vbTab & vbTab & _
       ActiveDocument.ReadabilityStatistics(2).Value
   msg = msg & vbCr & "Words:" & vbTab & vbTab & vbTab & _
       ActiveDocument.ReadabilityStatistics(1).Value
   msg = msg & vbCr & "Paragraphs:" & vbTab & vbTab & _
       ActiveDocument.ReadabilityStatistics(3).Value
   msg = msg & vbCr & "Sentences:" & vbTab & vbTab & _
       ActiveDocument.ReadabilityStatistics(4).Value

   ' first value,  in parens, is the calculated ratio
   ' second value is the one returned by the dialog
   msg = msg & vbCr & "Sen/Para:  " & Format( _
       CSng(ActiveDocument.ReadabilityStatistics(4).Value) / _
       ActiveDocument.ReadabilityStatistics(3).Value, "(= 0.0)") _
       & vbTab & vbTab & _
       ActiveDocument.ReadabilityStatistics(5).Value
   msg = msg & vbCr & "Words/Sen:  " & Format( _
       CSng(ActiveDocument.ReadabilityStatistics(1).Value) / _
       ActiveDocument.ReadabilityStatistics(4).Value, "(= 0.0)") _
       & vbTab & _
       ActiveDocument.ReadabilityStatistics(6).Value
   msg = msg & vbCr & "Char/Word:  " & Format( _
       CSng(ActiveDocument.ReadabilityStatistics(2).Value) / _
       ActiveDocument.ReadabilityStatistics(1).Value, "(= 0.0)") _
       & vbTab & _
       ActiveDocument.ReadabilityStatistics(7).Value
   
   msg = msg & vbCr & vbCr & _
       "From Object Model---------------"
   msg = msg & vbCr & "Characters:" & vbTab & vbTab & _
       ActiveDocument.Characters.Count
   msg = msg & vbCr & "Words:" & vbTab & vbTab & vbTab & _
       ActiveDocument.Words.Count
   msg = msg & vbCr & "Paragraphs:" & vbTab & vbTab & _
       ActiveDocument.Paragraphs.Count
   msg = msg & vbCr & "Sentences:" & vbTab & vbTab & _
       ActiveDocument.Sentences.Count
   
   MsgBox msg
End Sub

The case of the Flesch Reading Ease and Flesch-Kincaid Grade Level is
even worse. The published formulas for those scores involve the
average number of syllables per word. Nobody outside Microsoft knows
how Word determines the syllable count and the average -- presumably
it's based on the hyphenation dictionary, but it could be just a
rule-of-thumb estimate or a hardcoded average. You can't trust it.

So my advice is not to rely on any of these methods, especially if the
results will be used to classify documents for any important purpose.
Either get a piece of open-source software (not that I know of any,
but some academic must have written some) that can be calibrated
properly, or do a manual count of a representative sample.

--
Regards,
Jay Freedman
Microsoft Word MVP        FAQ: http://word.mvps.org
Email cannot be acknowledged; please post all follow-ups to the
newsgroup so all may benefit.