I'm not sure what version of Excel you're using - is it 2007? If so, the file extension should be .xlsx or .xlsm. If you rename a .xlsx file with a .xls extension you will get the error message shown when you try to open it.
To save the file as Excel 2003 add FileFormat :=xlExcel8 to the Save As line
.SaveAs TempFilePath & TempFileName & FileExtStr, FileFormat :=xlExcel8
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