S-XPS 1640 and 1645 Audio buzzing/cracking/distortion 60-80%+ volume (to Bill for engineers)

I tried everything listed in the thread on my Studio XPS 1645. The rattling starts when starting the notebook cold using it the first time after being off for a long period of time. The cracking bleeds through Breakaway. Breakway support said any sound present in the system will be pick up by Breakaway.

Dell has replaced the sound card, motorboard and the woofer. The cracking start about a year after I purchased the notebook. Dell support runs all their tools and update drivers with no results.

I have disable the wireless and use the hard wire to connect to the Internet. I still get the distortion after a cold start up. There does not seem to be any distortion after the notebook has warm up.