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!