I've had issues with publishing to PDF before. Annotative multileaders would go berserk, among other issues.
Solutions: (it may not be what you want are looking for...)
1. DWF: Publishing to DWF I have found to be the best solution to intensive memory plotting. Once the DWF is created, plot to other printers. The DWF remains a record copy and is also for markups
2. PDF: If you absolutely need a PDF (client's request), use DWG to PDF for only those sheets you know will plot correctly, then use another PDF print driver for the problem sheets. Personally, I use PDF Tools, Bluebeam PDF as well as the Autocad internal DWG to PDF in order to plot. Merge your separate files together and voilá. It's not pretty, but it gets the job done.
Nathan Selles-Alvarez, P.E.
Senior Civil Engineer