I'm not sure what is wrong with that file. If I were you here is what I would try - it's going to be long but the best idea I have.
Create a brand new wordpress install with the same version of the theme. open both sites up in two windows. Go theme page by theme page and copy the settings from the existing site to the new site. When you are all done, export the settings again and try to re import them into the new site - or attach them to a reply and I'll try importing them into a site.
"Tell me and I forget, teach me and I may remember, involve me and I learn." - Benjamin Franklin
Juggledad | Forum Moderator/Support