Here is my theory on what's going on. Basically what's going on is it's starting a siphon. This happens when more water is going in than is free flow draining. Now I realize nothing has changed, but in general the slime layer that builds up inside of PVC, that brown slime like stuff changes the diameter of the pipe by a little bit. This causes less free flowing water. You must have been right on the edge.
To fix it you could clean your pipes... I don't do this because the problem just comes back. You could put a ball valve on the return pump and dial it back a tiny bit. You could improve plumbing if there are 90 degree bends you could use 45 degree bends etc. This can sometimes fix it as well. Sometimes creating less back pressure could fix it also. If the end of the pipe is submerged in water, try it without being submerged and see if the problem is solved.