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Large Word document - export to PDF fails on MacOS and MS Word Web

bennie gibson 25 Reputation points
2025-10-24T10:57:00.47+00:00

Hi, I'm working with a friend who has WORD 2019 on Mac OS Ventura 13.6.9 He has a large docx file (2000+ pages, 15.7MB) which is exhibiting the following behavior: - if his TOC does not have hyperlinks activated, he can export to PDF with no issues - if he activates hyperlinks in the TOC (\h in field codes), the export times out with the error "can't export file". There was a problem connecting to the network" - this failure occurs after several minutes of apparent effort to export the document - if he reduces the size of his document <600 pages, the export with hyperlinks works fine - if he prints to PDF, he doesn't get an option for "best for electronic distribution" (hence, the hyperlinks are not active in the TOC) Any suggestions appreciated on possible solutions. Thanks!

MORE INFO FROM ADDITIONAL TESTING:

2 MS Word Documents: 1st: 2100 pages, 16MB, 2nd: 1700 pages, 12MB

With NO hyperlinks in TOC:

  • MacOS: both documents can be exported to PDF with no issues
  • Windows/PC: both documents can be exported to PDF with no issues
  • Word WEB: Export works for smaller (e.g. 1/2) document, fails to open for 2100 page document - still doing tests to see what size works

WITH hyperlinks in TOC to headers IN SAME DOCUMENT (no hyperlinks to external docs):

  • MacOS: export to PDF of both documents fail around 650 pages in size (error indicates "internet problem"
  • Windows/PC: no failures during export to PDF
  • Word WEB: failure of PDF export fails at 1292 for first document - still have to test 2nd document

I'd say this is not necessarily a "Mac issue" exclusively but clearly Word for Mac and Word Web appear to be doing something different for export to PDF that Word for Windows is not. I feel like this is not a one off situation as I've seen multiple postings in various forums about this and similar issues but haven't seen any clear resolutions (other than making the document smaller which would be problematic as this goes from a 2 volume set of documents to 4+ documents). Wondering if anyone else out there is currently seeing this issue - in particular on MacOS for files this size with hyperlinks in TOC. Thanks

Microsoft 365 and Office | Word | For home | MacOS
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  1. John Korchok 231.5K Reputation points Volunteer Moderator
    2025-10-24T15:23:42.67+00:00

    Try creating a new user account in System Settings>Users & Groups. Then sign in to that account and see if the problem still exists. If it's still there, or if you don't want to switch accounts, try uninstalling Office for Mac using these steps, then reinstall from the Subscriptions page of your Microsoft account.

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  2. Harold Milan 17,495 Reputation points Independent Advisor
    2025-10-24T13:27:37.8266667+00:00

    Hi Bennie,

    This isn’t a one-off issue it’s a known limitation in Word for Mac and Word Web when handling large documents with active TOC hyperlinks. Microsoft hasn’t published a definitive fix yet, but using Word for Windows or splitting the document are the most reliable workarounds for now.

    Windows Word, on the other hand, handles this locally with more robust PDF rendering capabilities, which is why it succeeds even with large documents and active TOC links.

    Workarounds You Can Try

     Split the Document Temporarily

    If feasible, split the document into smaller chunks (e.g., <600 pages), export each with hyperlinks, then merge the PDFs using a tool like Adobe Acrobat or Preview on Mac.

    Use Word for Windows for Final Export

    If you have access to a Windows machine, open the document there and export with hyperlinks enabled. This avoids the limitations seen on Mac/Web.

    Print to PDF with Hyperlinks (Advanced)

    On Mac, printing to PDF doesn’t preserve TOC hyperlinks unless “Best for electronic distribution” is selected which isn’t available in your case. However, you might try:

    Saving the document as a web page (.htm), then opening it in a browser and printing to PDF.

    Or using third-party PDF tools that preserve internal links during conversion.

     
    Let me know how it goes, Happy to help!

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