Chris,
There is a known issue with the DLL file usp10.dll that is part of the Crystal Reports runtime rendering certain fonts to PDF. Calibri is one that is known for certain, but other similar fonts may have the same issue. Here is a discussion on the SAP boards (with a suggested fix):
forums.sdn.sap.com/thread.jspa?threadID=...10&start=15&tstart=0
Before going too crazy tracking down DLLs and such, could you try a simple test to see if this is what is going on for you? Make a simple report using a very standard font like Arial or Times New Roman and export that to PDF and see if you see the same garbled font. Let us know what you get.
Thanks,
Adam