I kind of skimmed the last handful of posts in this thread - and DID read the first bunch thoroughly, and have a question.
For the folks who also experienced this issue, as well as the original poster of this thread, is it possible you had Windows also using the audio interface as the Windows Default Audio Device? If yes, then I would suggest that might explain some of the issues - as the ASIO specifications are written to only allow a single application to have control of a set of ASIO drivers.
So, if both Windows (playing of Windows sounds - mouse click, any of those dings/bells/whatever sounds that Windows plays - as well as Windows Media Player, playing a video on YouTube, etc.), AND Sonar are set to use the ASIO drivers of the audio interface, then there is a good chance of conflict.
I have been rock steady for years now, since I learned to split sounds off - I have Windows Default Audio Device set to use either a set of computer speakers, or the HDMI HD audio of the HDTV I use for my computer's display monitor, and it is ONLY Sonar that is set to use the ASIO drivers of my audio interface - and I NEVER have those weird conflicts like what some folks reported in this thread.
I recommend that you try testing setting the Windows Default Audio Device to something OTHER than the audio interface, and THEN see if Sonar works properly being the only application up and running pointing to the ASIO drivers of the audio interface.
(I do also have other music applications set to use the ASIO drivers of the interface, such as the stand-alone versions of Dimension Pro, Rapture, Rapture Pro, Kontakt, etc.), BUT I would only ever be running one of those programs in stand-alone mode at a time, and never also try to have Sonar up at the same time).
I hope the above makes sense - it is easy to test out, and if I didn't make enough sense, please let me know, and I will take another shot at explaining the above to make it clearer. :)
Bob Bone