It sounds like this may be a data issue. I would open the report in Crystal or VS and run it there against the the date that's causing problems. If there are no errors, then I'm not sure what's going on. However, I suspect there will be errors - if they're descriptive enough to show you what's going on, you should be able to fix the report. If not, I would go to the Database menu and select "View SQL". Copy the SQL and run it in a database tool for the date that's giving you problems. That might show you what the issue is in the context of the database.
-Dell