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Did you change how your sub was wired to your amp? Sounds to me, based on the information provided, your sub is running too low ohms for your amp. If you have a dual voice coil sub try wiring it for a higher ohm rating and see if your problem persists.

If I remember reading correctly, need to find that article, your sub needs less power in a ported box to achieve the same volume (loudness) at its port frequency than it does in a sealed box. This is because the port allows the air behind the cone to move more with less movement of the cone itself. In a sealed box it has to compress the air inside its box more which means more cone movement and thus more power is needed to do so.
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