SW does not use the same "tolerance" concept that some other programs use.
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I'm having problems exporting solidwork model into Pro/E ( surfaces didn't connected, surfaces weren't tangent to each other, edges of surfaces looked faceted not smooth, ....)
In Pro/E, users can increase the part's accuracy so that they get higher quality exported files (in iges, step,...etc), meaning the gaps between merging surfaces are smaller.
When I was using Pro/E, it had problems importing STEP. The classic was inverting spherical surfaces (imagine your corner fillets turning into round bulges).
You might try IGES, it tends to work better with Pro/E. Alsot try ACIS (*.sat). There are some export options that allow you to specify "high trim curve accuracy", as well.
On the Pro/E end, try changing from relative to absolute accuracy. Also, Pro/E does have some repair tools available.
I could be the world's greatest underachiever, if I could just learn to apply myself.
Maybe, I'm missing something , somewhere, but did anyone try the Save As/Pro-E option? We have moved models over to Pro/E from SW without translation problems many times, though I don't about the complexity of your particular model.
Regards,
Christopher Zona - Senior CAD Designer
Litens Automotive Partnership
Concord, Ontario, Canada