Also happens when no Intel apps or kexts are running at all. HALC_ProxyIOContext::IOWorkLoop: failed to send the final message to the server, Error: 0x10000003 HALC_ProxyIOContext::IOWorkLoop: skipping cycle due to overload Problem occurs more often USB 3.X devices rather than USB 2.0, switching between them gives instant pops on one but not the other.

On a similar note, my Mac Studio M1 Max is now randomly disconnecting ethernet when using cable. It's the only computer in the whole office with this issue, checking the router, it shows no reason for this to happen in the logs. This ALSO happened on my previous Mac Mini 2018 (T1 chipset) which also had this sound issue. So something is definitely wrong with how T1/T2 chipsets handle IO/Network.

I have a REALLY interesting development. My network connection kept dropping now and then, I use a high-end Mikrotik Router. So instead of buying a new one, I switch RouterOS to OpenWRT on it and lo and behold, the network never disconnects any more - HOWEVER, it ALSO fixed the sound popping and crackling issue! It's TRULY GONE! It seems that streaming media causes this issue to build up over time, some issue with the way MacOS handles media over the network. This is why this issue followed me through Mac Mini, Mac Studio and Macbook Pro, because I always used the same router. Please try with a different router (Or switch router OS) and see if this fixes it for you too and hopefully, Apple will see this and fix the issue!

Since no one seem to read comments, I'll just write a new post. Since I switched to a new router, I noticed the problem is 100% gone on ALL of my office macs. I can also reproduce this by downloading music locally, disconnecting the network entirely and restart - then play music and there is NO crackling, not even after hours. This tells me that playing media over the network is what triggers the issue, so please try with a different NEW router. I know it's only a temporary issue for travelers, but for offices it's a permanent fix.