We have similar problem with documents that contain overlays when the output is to .pdf. In our case, the overlay is shifted on the page and the data drops no longer line-up with the overlay text. The solution for us is to specify an offset for the overlay when outputting to .pdf, either in the OVRPRTF if you are using FRONTOVL/BACKOVL or in the DDS for the PRTF on the OVERLAY spec. We use .24 for the down adjustment and .05 for the across. This would look like FRONTOVL(MXBOL .24 .05). You have to specify this during creation of the file, though. You can’t do it on an existing spooled file. I hope this is what you are looking for.