So, it gets weirder! We did some testing today to try to isolate the specific circumstances and here's what we found: the line break issue only appears when you generate a test message, and then send that attachment as a message using Outlook 2011 (Mac). Once you do that, the line breaks are messed up in the attached test message whether the recipient is viewing them on a Mac or Windows machine. Very, very strange.
But, the actual test messages look fine when they arrive from Marketo, if you just forward (vs. attaching the message to a new email, which I do often so that I can send text & HTML versions for review in one email), they look absolutely fine.
So the good news is we discovered that our actual messages coming from Marketo are formatted correctly. Which is good, because I couldn't figure out how a plain text message was developing weird extra line breaks only viewable in certain circumstances.
Problem solves. But... weird.