All that suggestions you can/should try:
Delete all your types and then try to retype the unit to another type. Do not copy anything start from cratch. Setup a simple 2 Stereo layout. Disconnect the surround speakers. Does the crackling change with volume ? Does the surround channels also crackling when you have "stereo" or "direct" preset ? Have you swapped the position of cards before the crackling appears ? Try fetch from the 861 and see if all data are correct. List up the cards what you have and the position.
Good luck Robert
800v3/218/271/8k.2/5k5s  /5kC/DSP3200/Reviver/ TT-ELP/Graham Slee Revelation/Trinnov Altitude 32/OPPO 205 __Ayon/HB/Shunyata/Miltzow -- power cables, __Ayon/Jungson/Miltzow --analog, Miltzow-- digital, __Vortex/WMA ,
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