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Thanks for your suggestions. I've updated to ver 1.38, updated database as well1.38... Now its totally different issue :)

See: http://www.zen-cart.com/forum/showthread.php?t=83502

this might have to do anything ?
http://www.zen-cart.com/forum/showthread.php?t=48867&highlight=symlink

NO, I've tested with both options disabled. its same thing, in pdf it embeds page code at the end which changes the file size as well.

Thanks for your urgent reply. Download by Redirect is off and Download by streaming is on, as i might have some bigger files.
thanks

Hi,
I am having exactly the same issue, my downloads gets corrupted after downloading. I've gone through all of the steps mentioned in this post but its still there, I am running:
Zen Cart 1.3.7.1...