Hmmm ... I've just noticed that I don't seem to be getting /category-subcategory-product1.html type aliases. Just the product or category name is being picked up, i.e. it isn't going down through the levels. This is a problem when there are sub-categories that have the same name, e.g. Ladies Shoes->Casual and Mens Shoes-> Casual.
This looks similar to boraz's comment above.
Oh, and one more issue. Products links in the sub-categories won't convert (they look like: index.php?controller=product&path=23_41&product_id=1793). For the main categories it's working fine.
Thanks for help.
I'm not sure if he is also using the sub-category contrib, tho I don't think it is related. I will try it on my test site without my sub-cat contrib.
OK, just tried it and I am also seeing this issue, even without the subcats mod.