I've also had problems with it not updating reports correctly (or completely losing the DB info!) before, too. I never did dig into it to figure out what's wrong.

What I've done is make sure I keep the "Backup" option checked, and if it fails to update, I use Windows to copy everything back from the Backup folder into the Reports directory and run it again. Usually that works...

But honestly, I haven't messed with this lately as we're trying to move everything off of Crystal...

Sorry I can't be more helpful.