You could try plugging/unplugging things from the headphone socket and checking the phones responce in XTerm. I made an earlier post about it here:
http://talk.maemo.org/showthread.php...118#post844118
This will tell you if the device is switching input/output modes correctly.

It may sound really daft but you have adjusted the volume; phone earpiece, phone speaker, media player speakers, etc... all have a different and independent volume settings (as you have re-flashed I doubt it's this)