Tim,
I was just having the same problem and right now I have it fixed.
The problem is the config.php file located in the root of your Moodle installation. In this file just remove blank lines, spaces, returns, or anything else after the two characters on the las line where you find the character ?>
I'm exporting grades right now without any problem.
Good luck,
Julio Cesar
Gradebook
1.9 Gradebook not downloading to excel
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