Macbook stuck in headphone (optical digital-out port) mode. Plugging and unplugging headphone jack no help.

Stuck in headphone (optical digital-out port) mode. What do I do? Plugging and unplugging headphone jack no help.

Do you see a red light in the headphone jack?? If you do, then the microswitch is stuck and you need to turn it off. Try poking it with a toothpick.
If you don't see a red light, then try resetting the SMC and PRAM and see if these helps. Here are the links.
http://support.apple.com/kb/ht3964
http://support.apple.com/kb/ht1379

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    Just want to report that I too, running 10.6.5 on a MacBook Pro, had the mysterious " Audio Out Stuck On Optical Digital-Out Port" problem whereby I was unable to adjust the volume on my built-in speakers and they were permanently "muted" because the operating system was sending the audio signal to a non-existent device that it falsely thought was plugged in to my unused headphone jack hole. I thought at first the problem must necessarily be software-based because the built-in speakers worked fine when playing the start-up chimes. So I uninstalled something called "Soundflower" which does some mysterious shenanigans with commandeering the internal audio signal so that one can make audio recordings of one's computers' sound effects. But uninstalling Soundflower had no effect. So I uninstalled some other audio-related software, also to no avail. Then I zapped the PRAM, to no avail.
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