Here's my process.

Ripped with smart ripper
saved d2v with dvd2avi
avisyth
cce multipass vbr
pulldown
extracted chapter with ifoedit from original dvd
extracted sub with vobsub and converted w/ subtosup
complied with ifoedit

Everything works on the pc

in the set top it plays perfect, everything in sync, and subs are good. Okay here's the weird part...the dvd time counts the first 4 sec of the movie then stops. and the chapters work but if I advace to another chapter the video starts to stutter and dies. If I step back a chapter it always goes to chapter 1. Again, if I drop in the movie and just let it play through, it plays perfect. Any ideas?