I have a Facial Animation Profile I've created for this character which I'm trying to apply to a new instance of the same character.  
But the saved Facial Animation Profile won't load.  
Any ideas? Thanks 

Someone recently had the same problem with a saved profile. In that case the character had no or different items of clothing, which changed the vertex count. That may be the issue in your case. If it's not then I wouldn't know...

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Yeah, I've tried it with an exact copy of the character and a clothed version.  Same results.

Post a screen shot of the 3dxFaceAnim Profile.