wp-mail hack and post2cat table error

I’ve been customizing the wp-mail file to suit messages from my cell phone. I’ve had this problem on my production blog, but not on my test blog. At the moment it seems to be database related and not php.
When I run the file on my production blog it hangs for a while then finally completes. I check the main page and everything shows but the category. Thats where I get the error and it tells me to check the file template-functions-category.php line 65. That error is caused by the script not putting a new entry into the post2cat page.
I’ve even used a stock wp-mail.php file on my production blog and my test blog and it works on the test blog but not the production blog. My modified script also works flawlessly on my test blog. I thought I had it working perfect until I tried it on my production blog and got the error. All the settings for the table seem correct in my production database when compared to the ones in the test database.
I’ve been working on it all afternoon and now I’m at a dead end. It just seems like its lagging when doing the query on my production database, but I don’t know why. Any suggestions? Thanks