Hi Craig, I changed dll to dlx on 2014 versions but no difference so obviously not the ones I'm using.
The audio I'm having trouble with isn't REX it's just the direct audio out from a Reason module into an audio track in Cakewalk. Its when I record that audio it goes wrong, but only if it's coming from any Reason output other than 1+2 and if the midi that's playing that module is from Reasons own sequencer, if I send the midi from a track in Cakewalk to the module then freeze the instance of Reason it works perfectly no matter what Reason output I use. I've done this with multiple modules and suitable midi and audio tracks routed in Cakewalk, then frozen Reason and all tracks render to audio as expected.
This is obviously my way forward at the moment, just means I won't be able to make use of any of Reasons sequencing etc.
Thanks for your suggestions, and if anything else comes to mind I'd love to here your thoughts.
Roy