I had this along with serious syncing issues and I am also running Live 8.04!! I opted to install the latest beta version of the Virus OS and it solved my syncing issues and seemed far more stable, although a beta is not always for everyone!
I also encountered some strange issues when installing the new Virus software but think this was more to do with my pc.
I haven't had any of the nasty crashes with my setup, but I have had the Virus unexpectedly stop playing the second channel or all channels (no sound!) especially when I am using more than one of its usb outs.
Fix for me is usually to exit Live 8, turn off the Virus, soft reset (pressing arp edit while still plugged in) the virus and then start everything back up again. Seems to do the job!
Oh and the crackling in the same spot in your track may be down to hitting the red on some or all of the ableton effects plugins on your virus channel...I see this happen in some of mine when I have a big sounding 3 osc patch (usually bass) in the project. I was hitting a very short peek which Ableton hated and create a horrible stabby sort of pop on one or both speakers.
HTH