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[Matt]

I found a device we have here that would click during playback with certain buffer sizes.

When using 'Maximum' from Options > Audio > Output mode settings..., it could click periodically many times a second when playing at 44.1kHz.  With 'Maximum (power of two)' it would not click.

In this case, we talked to the manufacturer and they said "update your driver to this one."  We did the update the clicks went away, at all buffer sizes.

I was actually a little disappointed, because I was hoping we'd learn something that would solve the problem for anyone having this issue.  But in this case, it appears to have been a driver issue with certain hardware buffer sizes.  The latest driver fixes the problem.

So something to check if you're having this problem.  Trying the other buffer size settings (restart the program after each change) might also help.

[Matt]

I found another device that clicks using the 'Maximum' buffer size, but works fine with the 'Maximum (power of two)' [the default] and 'Hardware default' options.

I believe it's a driver / device issue.  It's possible not many programs (read iTunes) set the buffer size so that this isn't a common test case for hardware makers.  I'm not sure.