Where did you vent the air at? At the high point for each zone? Wouldn't be the first time a pump went out, or debris moved into the pump and caused a jambed impeller. You may need to call a heating specialist.
There must also be a flyable computer available for Nefarious to do FSO. So he doesn't keep talking about it for eight and a half hours on Friday night!
I haven't played much with water systems either, mostly steam. It sounds like you are going out on a high temp safety. I bet your pump is shot.A running pump doesn't make it a working pump. The gravel sound could be broken impeller blades grinding themselves into sand.
That little red pump doesn't have a replaceable coupling--it's direct drive. It shouldn't make much noise to speak of when it's running. You either have some sort of debris stuck in it or you're hearing the remnants of the impeller rattling around. When we have problems with them it's a throwaway. Usually a heating supply house item.
ahh im a retard.. you rattled me with 'direct drive'.. had to google it.. impeller bolted on the rotor.. I'd not thought of that but seems pretty common in this application..
Nef, if you're fairly handy you should be able to do this. Talking two pairs of nuts and bolts. A pair of gaskets. Kill power to boiler. Drain system or isolate the pump if you can. Disco the electric at the box on the pump. It's 110 so you only have hot neutral and ground. Hard to screw up. Unbolt. Clean flanges with a green scrubby pad. Put new gaskets on pump. Self explanatory when you see it. Slide new pump in. Bolt it up. Reverse the rest. Fill and bleed system.