Dear Tom, good to hear that minimal is working fine.

I had the same experience that you had with the Introduction not showing up in the TOC. Do you know how to report a bug?

I think that completecontent doesn't recognize the user defined "intro". It is all what I can tell you. If you have no special reason to define \intro, you may use \chapter to make it appear in TOC. This mailing list is a place to report a bug. If it is a real bug, then Hans will correct it, otherwise many experts who are watching mails suggest you a good solution. Thanks, Best regards, Dalyoung