Hi wjg
Have you tried this?
Expand your Single Source Layouts pseudo folder
Right-click the WebHelp layout and click Properties
Click the Next > button twice
Note the option setting for "Optimize speed for". My guess is
that it is set for "Web Site (Internet). If so, set it for "Local
PC".
What normally happens is that when this setting is set for
Web Site, the TOC/Index/Search/Glossary are split up into smaller
(and hopefully more easily shipped) chunks. But this can have an
adverse effect on synchronization. For example, let's say you click
a link to a topic. The topic tries to sync, but that particular
segment of the TOC hasn't yet been shipped. So the sync fails. By
setting the option for Local PC, the navigation is kept in a single
file. The trade off (there is always a trade off, eh?) is that it
may initially take a bit longer for the TOC to display. But it
should correct synchronization issues.
Cheers... Rick