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I've tracked down a bit more on this.
When is happening is that the Tm command triggers a font update. Part of this update checks that the substituted font is roughly the same width as the intended font, and scales it if not. For the paragraphs in question the getGlyphAdvance call is returning a value greater than 1 (which shouldn't be possible), causing the font to be dramatically over-shrunk.
This can be worked around by changing SplashOutputDev.cc, line 1177, to add a check for w2 <= 1.
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