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What could be some causes of a 20-30db difference in output with only the BFD added?
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Disregarding the VU LED's on the BFD, are you saying that the voltage level getting to the sub drops when you insert the BFD in-line between the reviver and the sub?
Are you sure you have the BFD channel 1 and/or channel two input and output jacks correctly oriented? They are very confusing.
The BFD is a unity gain device with the filters disengaged, so you either have the cables incorrectly hooked up, or the BFD filters are actually on and not bypassed, or you have a fault in the cables or BFD.
brucek