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Craig,
I went through the same issues, always leaking from a rear corner. In my opinion it was caused by poor gasket manufacture, both genuine and non-genuine exhibited the issue.
I wrote a summary here:
Td5 Sump gasket ..... why they can leak
Provided the correct installation procedure and correct location of sealant (in my case Permatex Ultra Black) is applied the sump stays tight. The use of a few pieces of sewing cotton tied through the attachment holes to keep the gasket in position during installation keeps everything in place during assembly.
I have seen gaskets recently that were better manufactured and I'm advised by staff at Graeme Cooper's that they fit and seal correctly out of the packet.
.......peter
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Peter-- I have added yours to the TD5 sticky in TGO,, :BigThumb:
my apologies it wasnt there sooner,,
its only been what? 3 years? :)