Having similar problems. I have a 101 page drawing set that I have made a set of DWF's from. We typically make a set of PDF's by printing the DWF's with the CutePDF print driver for delivery to our customers. I let my machine grind away on it for an hour with nothing else running, it finaly "finished" having created the file and put 4 drawings in there. one of which was missing the top half.
So far I'm not impressed with Design Review 2010. Does anyone know of a place to get back level DWF veiwers?
I did a couple searches and found Design Review 2008 still available from a CNET download site, I'm not sure of the forum policies on posting links so I won't. I downloaded the file, installed it and SUCCESSFULLY printed my 101 page drawing set in 4 minutes.