vshost32.exe crashes when Running Crystal report

Question

Im running an WPF app on Visual Studio 2010 (Platform x86). We're using a Client and server side using WCF. I've Implemented a Report functionality using Crystal by saving the report byte[] into our Postgress db, then when loading I load that into ReportDocument to get parameters then basically send that back server side and ExportToStream to create Report.

This has worked and has been running fine (old reports still do), but now we created a new Report and suddenly it crashes on ExportToStream popping up the (vshost32.exe has stopped working) box and the whole app crashes from there.

Is there anyone that encountered the same thing or can give me some suggestions? Been looking on Net but havn't found any real solutions.