What does the debug view look like when this is going on? Screen shots please on this.
Are the collision boundaries of the ebe structure in the way or not enough space for the character to get thru?
This was always the problem with halls and rooms being confined on each other. The engine needs a bit of space between things to be able to calculate a path around stuff. You can only have so small a range in the scripts.
Do your scripts have the player lookat in the scripts? I know that is still on range settings, not what should be seen.
The best approach I see with design is to give your self a decent amount of space for halls and walls for rooms. Maybe have objects around the edge of the room to keep AI that much further from the walls.
Intel(R) Core(TM)2 Quad CPU Q6600 @ 2.40GHz, 2400 Mhz, 4 Core(s), 4 Logical Processor(s), 8gb RAM, Nvidia gtx660, Windows 7 Pro 64bit, Screen resolution 1680 x 1050.