So, ash69 came by my desk to talk about this, then asked me to write up what's going on so he can keep his "one hit wonder" status. He likes being wonderful.
Your problem is pretty straightforward. The class in your project is x.lvlib:y.lvclass. The class in the packed library is x.lvlibp:y.lvclass. That single letter "p" is critical -- these two classes are not the same class. There is no guarantee that they have any internals that are the same -- in your case, they happen to have the same private data definition, the same function list, etc, but they are two completely distinct classes, and you cannot just convert one class into another class.
We can discuss at length why LV packed libraries are designed this way, but that's not going to help you with your problem.
The solution is easy to explain, and a pain in practice. You should build your class -- and only your class -- into a packed library. Then build your current packed library using the class packed library -- it will use the class packed library as a dependency, but won't suck it inside itself. Then use the class packed library in your project. After all that, you will have the same class in your project as in the packed library, and then passing data will work.
So, there you go. I hope that helps.