Cannot open default folders in cache mode

I did an upgrade on all my systems and installed office 2003 via a batch file.
I created the install template and all worked fine on fresh systems.

On systems with Office already installed (office 2000 / XP/ or 2003) the
install worked ok but the apps dont save their settings. Each time the user
opens Word or Excel (sometimes Outlook) the app is initalized for the first
time setup and the runs the progrss bar backwards, so it does not complete.

So far I have been about to correct this issue two ways.
First I need to update the office service pack for all.
1-- Use the profile wizard and import settings from a working system.
2-- Backup the users windows profile, remove it. open each app once. then
import the profile back in.

But about 1/2 the time on each fix above I loose my ability to run my
Outlook in Cache mode. Get an error unable to open default folder.
If I uncheck cache mode... works fine.

Is there as way to repair the cache mode settings so I can enable cache mode
on all my users again?

My Exchange server is off site so I really need cache mode, too slow
otherwise.

Thank you