This is a (6520) Digital 6 Plus? If so I had issues with the one on my Dart, it would pop a couple times after the gear change at the strip only. I tried everything you did plus changed the valve springs with no change.
Someone recommended that I change the rpm settings on the built in limiter. At the time I was shifting the 408 at 6400 with the limiter set at 7200. I dismissed the idea because it was popping after the gear change not before. The problem carried over to the 434 and got worse, to the point that after the 2-3 change it acted like the engine would shut off. It was running and would idle but not pull hard.
My local track had a street car shoot out on a Saturday and I had been checking stuff all week and wanted to make some hits to see if I had got lucky and fixed it. So the wife and I drive it to the track so I can make a few hits. Same old same old. Coming down the return road I remembered the limiter so when I got back to my pit spot and set it 9900 or something like that and went back out for another pass. It was a different car, no pop, bang and it didn't lay down. I made another pass just to see, it ran great again so I set both dials on 0 and it's ran great ever since.
Your mileage may vary.