And I gave you the most likely causes of the problem. No-one was trying to make you feel like a jerk - comments like:
in your previous response, shows you're happy to imply others are, though.

Assuming you have followed essentially the correct process, then without actually seeing the problem mailmerge main document it can be difficult for anyone to diagnose the issue. Can you attach the document to a post with a representative sample of the Excel data(delete anything sensitive)? You do this via the paperclip symbol on the 'Go Advanced' tab at the bottom of this screen.

__________________
Cheers,
Paul Edstein
[Fmr MS MVP - Word]