Well - Here I am again. Sorry about the late reaction, but there where some events (like old years eve combined with family) that kept me busy for a short while...
Anyway - I was able to solve the problem. I think it's good to tell what was causing it, and how I was able to solve it.
The problem basically was caused by the setup I was using with my old audio card (Focusrite Saffire Firewire - white standing model). This card has several outputs. The first two where routed to my monitors, and got an separate output bus with the ARC2 system inserted as FX. This bus was "branched" as a send from the Master bus. The second output bus had output 5 and 6 and was used as my headphone bus (with TB Isone inserted as FX). The Master bus itself was routed to the (unused) outputs 3 and 4.
The problem started because my new card (Focusrite Scarlett 2i4) only had 4 outputs (stereo 1-2 and 3-4), and Sonar got confused by the missing third output pair. This went so far that Sonar kept trying to assign this missing output and got itself in an endless loop.
The solution scook (thanks by the way - as an "old" user that started using sonar from version 6 years back, I should have remembered it) gave did not help very much, because in stead of clicking "OK" the loop kept on going without me having to click anything.
The solution, however, turned out to be very simple. I just disconnected the sound card, started up Windows and Sonar and the project, and all outputs where assigned to the generic windows ASIO drivers. Of course I got a warning that there was no suitable hardware present on the startup of Sonar, but after that I was able to load in the project. I saved the project with the new settings and shutted down Sonar and Windows.
I reconnected the sound card, started up Windows and Sonar and loaded in the project. Now everything went without any problem and I was able to re-assign the correct outputs (in a new configuration of course), and was up and running again with the project.
So - this story has a happy ending. The new year could have not started better (everybody best wishes by the way)... Thanks for helping guy's.