Hi, Nicole,
It sure sounds like you've been pretty thorough. Did you fix the problem last year?
Perhaps you could put something like a nylon hose over the return to capture some of it and make sure you're getting it from the returns.
I have heard of pumps being too powerful for the filter and actually forcing the sand thru the filter. I have never experienced that and it seems like your's was working at one time with that pump so that shouldn't be the issue.
To my knowledge, filter sand is pre-washed to get all the dust and really fine particles out before you put it in your filter.
As you can tell, I'm not much help...others will have more experience than me. Be sure to post back when it's cured......I'd really like to understand the cause.
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