If you have formulation for ex-cell look for incompatible reagents (e.g. magnesium and carbonate) that will form precipitates. Some media types can be incompatible because of this...
In the past I've grown SF9s on Grace's medium without any issues.
We normally use Grace's medium or SF900 medium from Invitrogen for our cell culture without any issues.
Also are you growing attached or in suspension? Have you tried just spinning SF9s out of Ex-cell and resuspending in Grace's? Could be a bit harsh on cells - but you could check make up of media to see how similar they are?