Actually, that was not the problem. The shaft is not tapered except up to where the gear mounts.
Many will frown with how I fixed it, and I am not happy either, but only way I know to get it running. Now that I know the process, the next install will actually be really easy.
The problem was I believe I had an O-ring that was out of spec. It was way higher than the shaft surface. Being it is a flat O-ring on each side means that since it was to large, it was compressing and bending "backwards" as I tried to install the pump.
For an visual explanation. Think of trying to install a piston into cylinder solid rings (no space) and no tool to compress them. Darn near impossible.
I had two options. Either use the old O-ring from the old pump or order a new O-Ring. I choose to use the old O-Ring which was only slightly higher than the shaft and it went right in. Still tight and took some pressure, so no doubt the O-Ring is sealed. With the O-Ring and the fact its bolted to the mount,I doubt it will leak. I can see where they could have simply used a gasket as well.
If I do get a leak, I can still take the other O-ring and try and put in the freezer for a bit before trying to install. But with how far it was above the groove, i just felt it was an out of spec O-ring.
And for the problem with the old pump. Appears there are several high pressure points, looks like ball bearings in the case. All were pretty much gunked over expect one. So that one was no doubt leaking enough to keep it looking like shiny new.
Anyway.. Thanks for the help and moral support. Sometimes it helps to bounce things off people instead of throwing good tools into the ground.
