Reset cables no change ?
I had some popping sounds and volume drop outs on mine. Re-pinned connectors and tried all sorts of things. The thing that worked was a new power supply.
Could be nearly anything - Prism card, cabling, speakers, amp, power supply... maybe an audio clip or video of the problem could clarify things? The easiest thing to replace is the PSU, you could always give that a try if detailed troubleshooting would be difficult.
Since the problem is intermittent does anyone know if the sound is tied into the prism card or is the sound board on it's own?
IFRC the black cable runs from the prism card to the audio amp across the case. some have suggested cutting the zip ties off that cable and flex and separate/wiggle the wires and leave them apart.
Worth a shot while you are swapping the PSU and might as well put a new fan/heatsink on the CPU while you're in there.
Yes, sound is generated by the prism card, goes to the amp via an interconnect cable. One of the lines on that cable is a 'mute' line, if that's not making good contact it could cause the sound to go on and off.
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