Hi Team,
agree with Neil as you say that the issue has only been evident since you worked on the transfer pump that is where I would start.
The packings may have been disturbed and likely being old and hard and so may not regain their sealing capability which is spring reliant crushing the rope/string packings.
The new packings are different to the old ones and so need to be compressed by steady pressing force and not Tamping as with the old ones-- or else they crumble apart--with the special tooling for the job--also you need the sleeve to install the packings over the sharp step on the drive gear shaft.
Press the packing only with the shaft, for the housing side packing and the sleeve inserted in the packing in the seat assembly(cone) or failure of the packing will result when the center crushes in when unsupported by the sleeve.
There are volumes written and lots of pix of failed new style packings etc. on this subject on the old BB but that seems to be history now--we live in hope that it can be recovered to this new BB.
Tooling drawings and new and old style packings shown in scans below.
From memory still later transfer pumps (maybe D8K) have lip type seals--people have made an adapter to fit these (one for the main housing and one for the cone) as they are a much surer seal--sorry, I do not have part numbers for the 2 lip seals but they maybe 4N4248 as from a D6 also with a half inch shaft.
The seal lip in the main housing faces inwards to seal pressure fuel in the transfer pump and the cone one faces outwards to seal the engine oil --
Hope this helps.
Cheers,
Eddie B.
Cheers,
Eddie B.

