Part 1 is here: https://e2e.ti.com/support/audio/f/6/t/809596
(for some reason the "add related question" button is not working).
We found the cause.
On "bad" boards the voltage at bypass pin (pin 16) is lower than on "good" boards. Approximately at 1.75 V there is no more sound at output.
Applying heat to bypass capacitor only (not to IC) decreases the voltage.
Our capacitors are 0402ZD105KAT2A AVX. They should have several MOhms of resistance and should not be a problem but there is a probably high-valued resistor divider on IC's input.
Therefore on some cases the capacitor can have an influence on the midpoint voltage.
There is almost no special requirements for this capacitor in the datasheet.
Can TI confirm us that our capacitors are correct?