Hi,

I had faced this issue but it is solved now.

This is how i implemented it:

I created a custom button with javascript code on it to call the webservice method. This web sercvice method in gets the visualforce page which is rendered as PDF, attaches this pdf to the outbound email and sends the email.

Here is the code:

code on custom button:

{!requireScript("/soap/ajax/16.0/connection.js")}
{!requireScript("/soap/ajax/16.0/apex.js")}
var idLead = '{!Lead.Id}';
sforce.apex.execute("sendPDFEmailClass","emailPdf",{a:idLead });

the sendPDFEmailClass

global class sendPDFEmailClass
  {
		/* WebService to send email with pdf attachment.
		   This method is called on click of Custom Button Email Pdf/
		*/  	
      WebService static void emailLeadPdf(ID leadId)
       {
     	  	
      		PageReference pdfPage= Page.sendPdfEmail;
     		pdfPage.getParameters().put('id',leadId);
       		 
       		Blob pdf1 = pdfPage.getContent();
     	        ...
   		Messaging.Singleemailmessage mail= new Messaging.Singleemailmessage();
        	....
           // Create an email attachment     
            Messaging.EmailFileAttachment efa = new Messaging.EmailFileAttachment();
           // neat - set name of PDF    
            efa.setFileName(lead[0].Name+ '.pdf');
           // set email body    
           efa.setBody(pdf1 ); 
         //attach the PDF     
           mail.setFileAttachments(new Messaging.EmailFileAttachment[] {efa});
         // send it, ignoring any errors (bad!)
          system.debug('Sending email');     
          Messaging.SendEmailResult [] r = Messaging.sendEmail(new Messaging.SingleEmailMessage[] {mail});
   
     }

  and the visualforce page should have  renderAs="pdf" in <apex:page>..

This worked for me.

Hope this helps those who are facing problems similar to this.