Jud,
I won't say this is a known problem, but I sure can imagine this to happen and it's actually a problem of the DAC which refuses to "stop in time". So, a last buffer is playing and in the mean time the sample rate is changed (after the stream officially stopped) which change is accepted by the DAC while still the old buffer with now inconsistent data is playing (annd I don't think this can reset because now some bytes have been shifted and that will remain so when playing continues).
If you think more towards "driver" instead of DAC, the problem may look more acceptable to happen (driver doesn't talk well to the OS while it is the OS which changes the sample rate).
Solution : Don't allow Format Changes (Settings).
BTW: Can I/How do I set XXHE to downsample 24/192 tracks to play through my DAC?
Nothing is in there for this. 24 bits can decimate to 16 bits though (e.g. 24/96 plays on a 16/96 DAC).
There's only one means of downsampling made available : from 24/352.8 to 24/176.4 (read, the others could be done just the same - I just never made it).
Peter