Some users have reported an error message when attempting to set up the DDE connection. When you preview or finish the merge, the zip codes will format correctly with leading zeroes (the way they appeared in the Excel spreadsheet).
Next, add merge fields to your main document (labels, envelopes, etc.). In the Microsoft Excel dialog box, under Named or cell range, select the cell range or worksheet that contains the data that you want to use, and then click OK. Click MS Excel Worksheets via DDE (*.xls), and then click OK. 
In the Confirm Data Source dialog box, click to select the Show all check box. Start the mail merge and then select your recipients by navigating to the Excel spreadsheet that contains your data. 
Click to select the Confirm file format conversion on open check box, and then click OK. On the Advanced tab, go to the General section. In Word 2010/2013, click File, and then click Options. In Word 2007, click the Office Button, and then click Word Options. Start Word, and then open a new blank document. Here is one way to fix the problem permanently: However, correctly formatted zip codes in Excel sometimes still arrive in Word without their leading zeroes. 
This is a particularly annoying problem because most users assume they are solving the problem by correctly formatting zip codes in Excel. When you use and Excel spreadsheet as a data file in a Word mail merge, formatting zip codes can sometimes make you want to tear all the hair out of your head.
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