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I normally leave all the EQ settings off.
Make sure all the other sound settings are sensible values too (e.g. Balance = 0%, Channel Configuration = Stereo, Stereo width = 100%, Crossfeed Off)
AFAIK (at least on the version of Rockbox that I'm running) the sound settings apply to both the line and headphone outs.
I can't think of anything else you could try at this point, other than trying to obtain another unit to compare to yours.
Have you tried the optical output? That has fixed volume, although I'm not sure if it's pre or post other sound settings.
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