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I had a similar experience. To fix the problem, the shop ended up using silicone sealant on the entire area-also knowing you are not supposed to use any sealant except for the half moon area. More than one year later it has held up!
Are you using glycerin (you could probably substitute using motor oil) on the gasket to allow it to float during installation? I know this is a pain in the a$$ job, took me like 4-5 hours per side on my Range Rover. Sucks to have to do again.
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01 X5 4.4 (sold), 99 Toyota Land Cruiser, 08 Ram 1500 Quad cab 4wd 6-Speed Manual, 06 Prius, 12 Camry SE.
"An armed society is a polite society"
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