Please, you're really going to HAVE to give better information. What do you mean by "dropping ouputs"? Are the outputs set from something to "none"? Are they unchecked in preferences? Are buses that used to be there not there? When you say you "fix," what do you mean? You insert new buses? Re-assign outputs? Re-do preferences?
And a sentence like this tells us nothing: "I know its broken because when I save and relaunch Sonar the audio will play."
Instead of just running to the forum whenever there's a hiccup, pause, and try to come up with a coherent description of what's happening, with the steps you take to reproduce it or fix it. Otherwise it's like going to the doctor's and saying "my heart's messed up." Well, is it beating too fast, beating too slow, arhythmic, heartburn, gas that produces a pain in the area of the heart, are you short of breath...who knows?