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IE is a bit broken with this stuff sometimes - it doesn't always believe/accept the mime type your script sends and thinks it can work it out itself hence the garbage...
what http headers are you sending? here's some that I've used in the past to send generated PDF content to a browser ...
header('Content-type: application/pdf');
header('Content-Dishahahahahahahahahaha inline; filename=my.pdf');
header('Content-Length: '.strlen($pdf_content));
header('Cache-Control: must-revalidate, post-check=0, pre-check=0');
hth
rich
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