Thanks for the speedy reply! The form is not currently browser enabled. I have checked off "Design a form template that can be opened in a browser or InfoPath", but I have not published it as browser enabled - that is something that I might be doing down the line. For the time being the form is only being used in the InfoPath client. I created the InfoPath form from scratch in the designer view of InfoPath a few months ago. The working version of the form has 6 data connections, 4 of which are retrieving information from a web server, 1 of which is a submit to a web service and the last (which is not in use) is an email submit. There is some code behind on the form that populates the form with the values returned by one of the data connections. (There are just too many fields to populate using InfoPath clicky-logic).
As for the word document. I started out with a word document that someone else had created for me. I added text to it to indicate where I wanted my fields to show up. I saved the document, copied it and renamed it to be a .zip file. I copied out the document.xml file and renamed it to transform.xsl. I opened the file in Visual Studio 2005 and made the modifications as described in your article and saved the file. Then I created the data connection: Tools --> Data Connections --> Add. I selected "Create a new connection to:" and "Receive data". I selected "XML document" browsed for my transorm.xsl (with All Files (*.*) selected). I included it as a resource file and told it to automatically retrieve data. After all that, I clicked on the preview button, that's when the problem I described in the first post started happening, At that point I closed the InfoPath form without saving - I opened it again at. (The last save had been just prior to adding the new data connection.) I tried the preview button & there was no problem generating the InfoPath preview - I tried readding the data conneciton, following the same steps and clicked the preview button again - same problem.
I'm not sure how much detail would be useful, and this post is getting quite long, so I think I'll stop here.
I will take a look at the alternative InfoPath to DOCX. But please if you have any ideas about what the problem could be, I would love to hear them. I know your solution works - I already made one successful InfoPath to Word conversion following your article and that one went off without a hitch, so I'm at a loss as to what could be causing this problem. The other form that I converted was quite similar to this one.
Thanks again for replying - I really appreciate it!