Hi,
You should first check if the problem is after the Programme or before (either on bus A,B or C). You can patch out the A,B,C and Programme at the patchbay and check when you push Ext.Mon if you can hear that click/pop. This will allow you to check if: 1 - the problem is in the audio or monitor path. 2 - if it's in the audio path, 3 - if it's in one specific bus, in the programme summing, or after.
There's also the possibility if it's only in the monitor path, that the problem is being triggered when you switch the monitor using the Ext.Mon. You'll have to figure that out with this type of divide-and-conquer approach to isolate the fault.
Having this information in hand it will help you isolate on the big diagram block schematic (that A2 diagram that's on the service manual) on which card the problem might be.
Then what I would do, is put the candidate card on the extender and probe the audio until I find the culprit. Typically the cards have an audio and logic section. The problem can also be on the logic side of things (or mechanical if the problem is in the switch).
Anyways, my suggestion is to start with the top approach and see where it leads you.
Cheers,
Artur