I have an update if anyone is interested. It finally happened when i was home.
the problem is a HDMI thing.
when i was changing the resolution on the cable box the other night from 1080i to 720p the volume did go full blast on me. BUT, it was the tv speakers only. For some reason the setting on the tv to turn the tv speakers off gets bypassed by the HDMI. when i switch the tv speakers setting to 'ON' then back to 'OFF' the tv speakers go back off.
this problem will only raise its head during some type of secondary HDMI connect, meaning it doesnt happen when the box is first turned on. It only happens in certain instances like when you do something with the settings causing the HDMI to reconnect. It also seems like this will be labled as a tv bug and not a cable box bug as i have a feeling the cable box is putting out audio on all connections at the same time.
there may be a firmware fix for this but im not going to be updating the firmware on the tv just to fix this once in a blue moon audio problem that can be fixed faster by changing a cable. to bad i couldnt get to the speaker wires or id clip the dang things.
again thanks for all the ideas and help people.
EDIT- found this on the samsung thread from 2008 years ago. it took two years for this issue to raise its head.
From Samsung Firmware page:
* This firmware will correct the following phenomenons some units may experience.
-. Intermittent audio drop out
-. AMP(Auto Motion Plus) stuck
-. do not memorize ''SRS'' setting
-. The audio comes from speaker when loading the CD(Game title)
though ''Internal Mute'' is on(speaker is off)
If that's not the issue, I'd suspect the HDMI handshake between TV & Receiver. Possibly even the cables.
Have you tried connecting with component cables instead of HDMI from Sat box or DVD?
Last resort is open a ticket with Samsung, and let them send a tech out.