Nothing i did would or should have made my pet lean towards Elder at ANY point. The only reason the pet died that ONCE outside Ice Tooth is cause i had gone afk forgetting i was still outside, i was in a rush to get the door.
First of all, i am a VERY experienced Beast Master, and in fact have lvled pets to dire in Prophecies MANY times without problem.
Second, i never allow my pets to take much dmg at ALL. I ALWAYS have Symbiotic bond + Call of Protection on, and i have never seen my pet lose more then maybe 30hp (or some such) at any time (in other words, a real little bit). As a fellow Beast Master you know what i mean, when lvling you barely ever see his hp bar drop much at all to achieve Dire.
Third, i use a trapper staff. Since i automatically cant reach the req for the staff, i do crap dmg (maybe 1-9 dmg). Even my pets auto attks do more at only lvl 5. I always bring large dmg pet skills i.e. Enraged Lunge, Predators Pounce, Feral Lunge, etc etc. He has always done more dmg then me during training.
Fourth, at lvl 10 he DID get the Aggressive title.
A few things i am contemplating. Apparantly to reach Elder, which is between Hearty and Dire, one has to raise the pet in two stages. First stage leaning towards Hearty OR Dire (taking more dmg or doing more dmg respectively) and the second stage training leaning towards the opposite of the first stage. Now that is NOT what i did, since i DID get aggressive and continued to train him in the same manner he SHOULD have hit DIRE!!! I think your leveling method has cursed me. LoL.
I seriously have thought over and over and over about what i have possibly done to make him Elder, but i seriously have NO clue. Dying only once would not affect his evolution whatsoever, plus he was like only lvl 5 or 6 at the time. I guess i was just hoping for some1 to speak up who had the same experience, but... ya... Random bugs like this seem to happen to me a lot. Eww!
Oh well, kinda kewl to have a Elder. I don't get +2 dmg/-60hp for being Dire, nore do i get -2 dmg/+60hp for being Hearty. I get +0dmg/+0hp, the happy medium in between!!
EDIT:: Well to answer your questions more specifically Lennymon:: Of course my BM is at 16, I never do more dmg then my pet, and since the pet only goes after a target you are ATTACKING (calling doesn't affect his reaction), i continue to attk the target to ensure my pet stays on target (again, i do WAY less dmg then my pets auto attks.) Anywhoo, i guess this is just one for the books eh?