If possible try with another pair of headphones.
If speaker outputs are ok, probably indicates a faulty output of headphone amp, if is seperate circuitry from speaker output.
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You are connecting a NOISY unbalnced line to a balanced input. Buy a DI box and then use an XLR to XLR to the mixer inout and run the MAC into the DI with "ground lifted". You will need to make a resistive mixer between the headphone jack and the DI as well. The headphone jack is STEREO. You COULD try a STEREO 1/8 inch splitter to 1/4 inch left and right cable... you MIGHT get away with that. Right now the left and right amps in the MAC are fighting eachother.
There are two devices involved and you've only defined one.
What are you feeding the headphone jack TO?
Maybe it's the headphones (?) themselves that are distorting.
Wild guess... if you're plugging the output into "PHONO" on something it WILL distort above a very low level. "PHONO" is the only input in audio that is literal and exclusive. Turntables ONLY.
Use another input.
Google "RIAA equalization" for further info on that subject.
Does the distortion ALSO appear when you listen with headphones? If not, the problem may be downstream. The driver for the mute control line to the mute transistors may have a problem. Make sure the mute is off.
Sounds like a bad headphone jack. Contact Apple at 1-800-275-2273 (1-800-APL-CARE) if it's under warranty. If not, find an iPod repair company to see if they can re-solder the headphone jack.
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