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So you moved him OUT of the pen that had all your roos, then back in?
I've noticed whenever I move roosters around between pens, they always have to reestablish the pecking order, even if it was just the next pen over. By moving him you disrupted the "peace", and now they all have to reestablish themselves.
Sometimes this just takes a few pecks, sometimes they will all gang up on the "new guy" and he can never be reintroduced- just depends on your situation.
We had a "main pen", large and roomy, all chickens were in it. everything peaceful. Rotated some hens to "infirmary/isolation cage". As they got better, they were rotated back, with aprons on. Wanted to have fertile eggs from imfirmary cage. Choose most gentle roo to go in there (Pretty Boy). Infirmary cage in garage, large coop is outside. Now want to reclaim infirmary/isolation cage back so I can add to my flock. Let everyone free range and "work out the buggs". Big mistake. Most agressive roo, (Lacy) got bloodied on face. Most handome/ gentlest roo, Pretty Boy, cannot find his pecking order. Is challenged by other 3 roos constantly. He will run for a while but then he won't back down. Our king roo, Elvis, outweighs every one else, some by 2 lbs. Elvis won't stop chasing Pretty Boy. Can't get rid of either. Elvis is DH's pet and the best protector of flock, Pretty Boy is my pet and a show stopper!
I agree, as WMR, said--they had an established pecking order, which was fine because the roos, I assume, had grown up together and they understood their place in the order. BUT, once you took one out (+ the hens, which was also a disruption), the pecking order was thrown all off. Elvis was probably fine with them being in there because they were not breeding or a threat to his dominance...until Pretty Boy came back from the hen pen! My guess, unfortunately, you won't ever be able to put them back together.
Here's my experience:
--out of my first ever Amer. hatch (2 roos, 2 hens) they were fine together, then all of a sudden that was it--not anymore & they had to be separated.
--out of 2nd hatch (2 roos, 1 hen), all were fine together. After a few short introduction visits, I put the hen & 1 that I thought was a hen into the pen with my main roo & top-dog hen. There was some bickering (oddly, mostly from the hen & young "roo"), but it settled down. I realized my mistake after a few more weeks when spur buds starting coming in. Still 2 yr old roo & this young roo were fine because the young roo was submissive and he wasn't trying to breed any of the hens, so the older roo didn't care.
--ended up selling both the young roos from that 2nd hatch, and even after growing up together and being separated for only a few weeks, there was NO putting them back together for delivery.
--put another young roo in a separate pen with only his momma (she had not "raised" him though) and she was super mean to him at first, then he started pecking back at her. Now, they are "okay"
--fall of 2009, I put a large young rooster in with my laying flock which had never had a roo. The hens really picked on him at first, and I didn't think it was ever going to work out. But he finally matured enough to stand up for himself, started crowing, and now he's "the man".
In short, I think a lot of it is a gamble. Sometimes, no matter how you carefully introduce or what the situation they just won't settle down and one be submissive. It does take time and it helps to "introduce" them slowly, I think...unless they're roos of a mating age and there are hens involved, and then I don't think that will ever happen.
Good luck with it all!
