Most of the formatting issues can be solved by updating below registry settings. I see that font size in report output is 10, it should be 9.
Open registry editor in the machine where crystal server is installed.
Go to this path “HKEY_LOCAL_MACHINE\SOFTWARE\WOW6432Node\SAP BusinessObjects\Suite XI 4.0\Crystal Reports\Export\Pdf”
Update the value of “ForceLargerFonts” to 0 (zero) and restart the crystal server and then generate the reports.
After the changes of above settings please re-generate all the reports which are provided to us, it should solve most of the issues. For any issues which doesn’t get solved even after the setting changes, please provide us output from older version and newer version to compare.