I can now present to you the first measurement (inside my 1040STE) of the audio crackle with fenarinarsa's test program:
I measured at U500, one of the flip-flops that latch the sound data for the DAC. The yellow trace is the load/clock signal; with every rising edge, new data is loaded into the flip-flops. The light blue trace is one of the data bits going to the DAC. As the DMATEST programs plays a buffer consisting of only zeros, it should stay low all the time. Whenever one of the flip-flop outputs (=DAC inputs) goes high erroneously, you hear a crackle or pop in the audio output.
Now, why does the data bits go high? The purple trace is the
input to the flip-flop. The STE Shifter is known to suffer from ground bounce - I have shown this in earlier investigations already. And this is precisely what happens here! The "spike" in the input coincides with the rising edge of the load signal. As you can see, it does not reach proper "high" level. This is why the crackling sounds random, the spike does not cause the output of the flip-flop to go high every time.
Fortunately, this means this should be fixable. Let me think about a solution...