This sounds like an issue with your mail server, and not Dada Mail then, unless the manipulation of the message is happening before being passed to the mail server, which I'm not feeling it is? If the manipulation is happening before messages are being passed to the mail server, I'll look at things. You can set Dada Mail to send just to a file with this config:
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$MAILPROG = '/path/to/a/test/file.txt; $MAIL_SETTINGS = ">$MAILPROG"; $MASS_MAIL_SETTINGS = ">$MAILPROG";
If you're sending a message with lines measured in the thousands, you're sending a message without any proper encoding. Can't comment on the php mail() command - Dada Mail is written in Perl, so wouldn't be using that.