A security update to Office 2007 back in June 2009 caused a number of problems. One impact is that document variables can be affected when you edit and save a document.
In some of our templates the problem is manifested by the headers and footers corrupting to Chinese characters.
We had assumed that Microsoft has resolved this problem but we had a client struggling with the problem earlier this month, February 2010.
A fuller description is available on this Infoware post. This directs you to a patch fix at this Microsoft page.