Thank you for posting your question in the Microsoft Q&A forum.
Based on your information, there is a high possibility that Excel is still running in the background or locked by another process, preventing Word from merging.
We kindly suggest you should double-check these things
- Make sure you disable the Preview Pane of File explorer via File Explorer > go to View tab > uncheck Preview Pane or completely close File explorer. This will prevent the Preview Pane from keeping a lock on the file while it is displayed
- Check if the file is syncing via OneDrive or another cloud service. If so, wait for the sync to complete or pause it temporarily.
- Ensure Excel is completely closed via Task Manager (Ctrl+Shift+Esc on Windows) > Details tab > look for any EXCEL.EXE processes > select them and click End task.
I hope this information is helpful. Please follow these steps and let me know if it works for you. If not, we can work together to resolve this.
Thank you for your patience and your understanding. I'm looking forward to your reply.
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