Send & Receive Issues

Fix Excel Cannot Send PDF Through Outlook: General Mail Failure

Maira Mehtab Sep 22, 2026 869 views

Question details

The user is unable to send an Excel workbook as a PDF via Outlook using the built-in share feature, encountering a General mail failure or default email program error.

Product: Microsoft Excel and Outlook
Device & OS: Windows
Scenario: Attempting to share an open Excel workbook directly as a PDF email attachment using File > Share > Email > Send as PDF.
Observed behavior: A General mail failure or default email program error message appears, failing to create the email, even though Outlook is set as the default app and an Office Online Repair was already attempted.

Before you start

Verify that Outlook is properly installed, has an active working email profile configured, and can send and receive emails independently before troubleshooting its connection with Excel.

Solution 1Recommended

Verify Default Mail Client Settings and Repair Registry

Ensure Windows correctly recognizes Outlook as the default mail application and resolve underlying registry conflicts causing the communication failure.

The 'General mail failure' often occurs when Windows registry settings for the default mail client are corrupted or misconfigured. This can happen even if Outlook appears to be selected as the default in standard system settings.

Check Default Windows Apps

Go to Windows Settings > Apps > Default apps. Scroll down to 'Email' and ensure Microsoft Outlook is explicitly selected.

Back Up the Windows Registry

Press Win + R, type 'regedit', and press Enter. Go to File > Export to create a full backup of your current registry to a safe location.

Apply Registry Fix for Default Mail Client

Navigate to HKEY_LOCAL_MACHINE\Software\Clients\Mail in the Registry Editor. Ensure the Default string value is set to Microsoft Outlook. If conflicting keys exist, follow Microsoft's official documentation to modify or remove them.

Restart and Test

Restart your computer to apply the registry changes, open your workbook in Excel, and try using File > Share > Email > Send as PDF again.

Registry Warning: Always back up the Windows Registry before making changes, as incorrect modifications can cause serious system instability or boot failures.

Solution 2

Create and Test a New Local Windows User Profile

Determine if the general mail failure is caused by a corrupted Windows user profile rather than a system-wide Office installation issue.

Free Microsoft Office alternative

Use WPS Office to Easily Share Spreadsheets as PDFs

Avoid complex registry fixes and Microsoft Office communication errors. WPS Office is a lightweight, free alternative that offers built-in PDF conversion and seamless email sharing without compatibility headaches.

1. Open your file in WPS Spreadsheet: Launch WPS Office and open your existing spreadsheet document.
2. Export to PDF: Go to the 'Menu' or 'Tools' tab and select 'Export to PDF'.
3. Share via Email: Once converted, use the built-in share feature to attach the PDF to an email in your default mail client effortlessly.

Highly compatible with Microsoft Excel (.xlsx) formats.Built-in, one-click Export to PDF feature without relying on external plugins.Free and lightweight, avoiding complex Office installation or registry errors.Familiar user interface for a zero-learning-curve transition.

microsoft office alternative - wps office

Frequently Asked Questions

Why does Excel say General Mail Failure when I try to send a PDF?

This usually happens because Excel cannot communicate with Outlook due to a misconfigured default mail client in Windows or corrupted registry entries, preventing the MAPI (Messaging Application Programming Interface) from initiating the email.

Can I send an Excel file as a PDF without using Outlook?

Yes. You can manually save the Excel file as a PDF using File > Save As (choosing PDF format) or Export > Create PDF/XPS Document. Once saved, open your preferred email client (like Gmail or Yahoo in a web browser), create a new email, and attach the saved PDF.

Does an Office Online Repair fix email sharing issues?

Not always. While an Online Repair fixes many Office file corruptions and program errors, it often doesn't resolve deep Windows registry conflicts related to the system's default mail client configuration.

Outlook & Email Problems