Oh no - big Photoshop Actions problems

Good Morning!

I'm in a right old pickle, and could you some Photoshop wizardery.

I'll go in to as much detail as possible, so try not to get lost...

We have lots of Actions setup for the various products we design. These Actions when run, will take the image/product we have and resize, save, resize again, and save again in various locations across a network. We've had these actions since way back, like CS2, and they've worked like a dream right through to CS5 for a short while, then all of sudden, BOOM, when it comes to the save file command in the action, its starting renaming the file to a file thats already in the destination folder - resulting in wrong file names for images, let me explain further...

example:

i have a destination folder called MUSIC POSTERS (one of many folders the action saves to) on a backup computer on the network.

In this folder i have:

GUNS N ROSES.jpg

MOTORHEAD.jpg

EMINEM.jpg

If i take a new poster, say motorhead.eps and run the action, it will resize ok, but the save command will then place the name EMINEM in the save dialog!? resulting in us having a motorhead poster called EMINEM.jpg and the original EMINEM.jpg file overwritten!

I'm aware of the fact that if when writing an Action and you manually type a file name into the dialog, it will record that name and use from there on out, but i certainly didnt do this, and it's worked fine for years.

Upon looking in all the folders it saves to - it saves correctly to only one folder, this folder is on the same drive as 2 of the other folders which it doesnt save correctly to 0 which makes me think its not a problem with the drive on the network (because its managing to save at least one correctly.)

I've tried a couple troubleshooting's - re-written the action many times, tried storing and loading/using the actions from a folder on my Artwork Partition (my computer is partitioned into SYSTEM, and ARTWORK), and also tried storing and loading/using the actions from within Photoshops Actions folder within the applications folder.

Problem No.2 - occassionally the steps within actions will rearrange themselves, duplicate themselves, or even remove themselves!

Any clues please?

just downloaded and installed latest patch, still no luck.