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Checked the against the most recent file for the php5.4 patch and there were a few lines of code that were different.

Updated the file but the issue still occurs. Tried adding a download product...

Just compared the original includes/modules/pages/checkout_shipping/header_php.php to my existing one and quite a few changes. It looks like it was patched using zen-cart-v1.5.1-php54-patch
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Thanks for the help - will start the hunt and get back with the results.

I am attempting to add a downloadable product and am hitting an error in the shopping basket when clicking on proceed to checkout. The error in Firefox and Google Chrome is The page isn’t redirecting...