I just spent about 10 hours trying to work out a bug. Due to an upgrade of httpd, a DB migration and a lovely IE bug all happening at once I was thrown in all the wrong directions. Anyway, I thought I'd post this here in case anyone else runs into it.
Basically, our admins upgraded to apache-2.0.40 and it totally whacked textareas in our forms. It appears there's a bug in that version, combined with php that causes text areas to double in size after hitting submit. This isn't happening in the production server, only the dev. I compiled a custom module for the dev machine, the prod machine is using the rpm.
Here's the fix:
http://bugs.php.net/bug.php?id=19263
Hope this saves someone some time.