Describe "wierd format", or better yet attach an example. To protect any sensitive information you could create dummy data or use one of the SAS supplied data sets such as SASHelp.Class to provide an example.
Have you looked at the log for the SAS job? Are there any notes or warnings? If so post them.
Have there been any changes to your software such as a SAS update applied, which one?
Have there been any changes to the configuration of your email server?