Not a seamless move to Sonar X2 - HELP!

Hi - I also have the AudioBox 1818 VSL interface, and am running X2a on Windows 8 x64.
 
Let's start by looking at some of your settings.
 
I run quite happily with the following:
 
For the audio interface: Sample Rate 48k, ASIO Buffer Size of 128.  My driver version is shown in the interface UI as: 1.57.0.5385, although the download file for it says something different.  
 
For Sonar X2a, I also have a Sample Rate of 48K, with a driver mode of ASIO, and of course I have my Presonus AudioBox 1818 VSL is the selected audio interface.  My record bit-depth is 24 bits.  My reported latency values in Sonar are: 
 
Input: 4.7 msec, 224 samples
Output: 4.7 msec, 224 samples
Total Roundtrip: 9.3 msec, 448 samples
 
Try those settings with that version of the interface and report back.
 
In addition, you may have latency interference by software running on your system.  Download and run the LatencyMon program without Sonar running, and take a look at what might be causing latency issues for you.  (last I heard DPC Latency Checker does not report accurate times on Windows 8, so LatencyMon is the best bet).  Sometimes, things like antivirus software and wireless adapters and such can interfere with audio streaming for applications such as Sonar.
 
Also, make sure your Windows is at current patch maintenance levels, and make sure you have X2A installed, and not just X2.  (X2a addresses more than 250 bugs from the base X2 version).
 
Lastly, some plugins can cause crackles, pops, dropouts, and other noise, due to the way they are designed to work.  To test this out, load up one of the projects giving you these extra noises, and hit the letter 'E' on your computer keyboard to toggle off/on all effects for the project.  If this makes it start playing back without the noise, then one or more of your effects is likely intended to be used for mixing/mastering, and not tracking.  When done checking this out, hit 'E' again to turn effects back on.
 
Please review the above and post back.
 
Bob Bone
 

Hey Bob, I made some changes, sample rate and buffer size and bingo! It's sounds okay!
 
One more problem though - nothing coming through the headphones. 
 

Just the normal output directly to the phones. I'm sure it's something simple. Will have a closer look later. Thanks.