Something that I've done with Outlook 2007 on one of my remote users is Exchange over HTTP. My remote user can recieve their Exchange mail anywhere, as long as have internet connection. Works great. Look at the attached file and let me know.
I have tried the MTU test already as well (sorry, should have mentioned that). I have also set the firewall to ICMP back to exchange with 'Fragment' if the packets are too big.
No difference.
I have also tried it with Outlook 2003 and surprisingly I get the same issue...
Not too keen on RPC/HTTP - unsure why! Will try that as an absolute last resort. It'd be a bit of a defeat ;o)
I have been concentrating on M$ issues but I think it may be more the firewall / routers. I'm going to start some packet sniffing today and see exactly what gets dropped / what communicates with what.