Here is a good solution found on apple discussion forum!
I finally found the root cause of my problems for this. The problem for me is with file permissions on the 2 Audio plist files. For some reason during the 10.5.6 upgrade they are not set properly. Looking at the all the answers on the forum that seemed worked for one reason or another confirm they are related to file permissions.
I also have a permanent, reasonably easy fix for it. To fix the permission problem, you need to change the ownership of the files as described below.
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Launch Terminal from Utilities folder. This automatically logs you in as yourself.
To change file ownership, your need to switch login as root. Follow the commands in bold. I left the detailed listing so you can see what to expect. You can copy and paste the bold text into Terminal as they are to save retyping.
Note the ownership change from "jdoe" to "_coreaudiod"
unix$ sudo -i
password: type your normal user password here
unix# cd /Library/Preferences/Audio
unix# ls -l
-rw-r--r-- 1 jdoe admin 3149 11 Nov 22:17 com.apple.audio.DeviceSettings.plist
-rw-r--r-- 1 jdoe admin 1363 11 Nov 13:06 com.apple.audio.SystemSettings.plist
unix# chown _coreaudiod com.apple.audio.DeviceSettings.plist
unix# chown _coreaudiod com.apple.audio.SystemSettings.plist
unix# ls -l
-rw-r--r-- 1 _coreaudiod admin 3149 11 Nov 22:17 com.apple.audio.DeviceSettings.plist
-rw-r--r-- 1 _coreaudiod admin 1363 11 Nov 13:06 com.apple.audio.SystemSettings.plist
unix# exit
quit Terminal
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all the commands without the surrounding text for easy copy & paste
sudo -i
cd /Library/Preferences/Audio
ls -l
chown _coreaudiod com.apple.audio.DeviceSettings.plist
chown _coreaudiod com.apple.audio.SystemSettings.plist
ls -l
exit
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change your Sound Output setting
see if the timestamp changes on: com.apple.audio.SystemSettings.plist
the other plist will change after restart
restart your Mac and see if it works
good luck!
If this fails for some reason, I have another way of changing the setting that works but is not preferred. You can edit the plist directly to change the Sound Output but it is harder to do and does not sync with System Preference changes.
Try it!
This works if the files exist. I had no current files because I deleted them trying to fix. I used this after creating the Audio directory:
chown -R _coreaudiod:admin /Library/Preferences/Audio
The files will be created when you set the speaker/volume and any file in the Audio directory will get the correct permissions too.
Thanks for the info. Where did the _coreaudiod user come from?