Test access on email router shows success because the email router does a telnet to the SMTP server on port 25 that you mentioned in outgoing profile and if the telnet succeeds you get a success message. However your emails might be stuck in pending state for reasons like your email router does not have the relay permissions to relay the emails through the SMTP server. To verify this you can login to the Email router server, open the command prompt and run the commands below. Note that if you mistype even 1 character you will have to redo the entire process in a new command prompt window.
c:\>telnet SMTPserver 25 (hit enter), you will get the below response
220 SMTPServer.domain.com Microsoft ESMTP MAIL Service ready at Sat, 2 Feb 2013 18:25:15
helo (hit enter)
250 SMTPserver.domain.com Hello [server IP]
mail from:user@domain.com (hit enter). At this stage if you get 5.7.1 Client not authenticated or 5.7.1 Client does not have the permissions to send the email.
If you hit the message - 5.7.1 Client not authenticated, it surely means that your email router server doesn't have the relay permissions to relay emails through SMTP server. Ask your exchange administrator to provide the relay permissions to the email router server IP in order to relay permissions to relay emails through SMTP server. This is applicable for Exchange 2003, 2007, 2010.
If you hit the message - 5.7.1 Client does not have the permissions to send the email. You need to ensure that the credentials that you provide in the outgoing profile are that of a Full Exchange administrator and has the ability to send emails on behalf of all the users.
If above issues are taken care of your emails should be routed out successfully and should be in sent state and not in pending send state. You can look out for additional errors in the Event viewer on the Email router server under the application logs.
