Sorry, i've been busy at work lately and i just come home and start playing Dark Souls 2 to relax, so i haven't been able to post a whole lot on the issue. The section in question is the pivot from the headband to the arc that supports the housing, the right one to be exact. It did this clicking sound sometimes, every time i opened the headband so i could put the headphones on. Can't remember who said it in this post a while ago (just before this thread came back to life), but i had the same issue, and then suddenly, the cracking got a lot looser, and the grip of the headband was completely gone. It had a cylinder inside the little box that has the pivot, and that broke in two pieces, one that stuck to the housing, and the other one to the headband.
I fixed them, though they don't "feel" the same as before. I wish i could post pictures, but i left my SZ2k at home, and i work on another city, but i go back in around 2 weeks, and i should be able to post pictures so i can show you guys the issue.