Alright so, I got this fixed, hope this post offers some sort of insight for you too Coleo. You mentioned that it came back to life when you connected a cable from the send to the return. I'd already tried that, tone, volume, and dynamics were terrible with a cable in the loop or nothing in the loop. However, your post got me thinking... the Road King has 2 effects loops. I only use effect loop 1, and haven't touched loop 2 in months, but figured it was worth a shot to try plugging a cable into the send and return of loop 2. As soon as I tried that it came back to life, and remained fixed after I took it out. Everything sounds fine with a cable in loop 1, in loop 2, or nothing at all.
All I can figure is that for some unknown reason, the amp was picking up something I believe in the send jack of loop 2, as if a cable were plugged in there. Weird. I was getting a little bit of noise that comes and goes, some random distortions, even with the guitar's volume knob rolled down to 0 on higher gain settings. But last I was playing, they had gone away.
So, with your problem... are you only having it when you have the loop engaged but nothing in the jacks? You said it sounds fine with a cable plugged in. How does it sound with your board in the loop?
I feel so bad for my amp. Tried swapping so many tubes today, so much powering on and off. Ugh.