Dodo/Tony,
Yes - we hoped it was fixed with SP5 but it broke again last Friday (we are now at SP6).
We've seen it off and on for over 2 years (since SP1), the server simply refuses to deliver items when they have these kind of attachments. You can get the html version OK and even restore it.
It only happens about once a quarter which makes it hard to troubleshoot. You kinda sit there thinking "is it the compression thing again?", then you reboot the server to fix it, and then you think "ah crap, I should've done a Dtrace"....
We had a support call in about 18 months ago but there's not much they can do unless the box is actually exhibiting the symptoms. Hopefully next time it goes it won't be in the middle of the morning and we'll have a chance to troubleshoot as no-one on the forum seems to have seen it before. Lucky us ;)
I'm going to guess at an AV lock of some kind as the route cause at the moment.
Thanks for your help
David