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I have replaced the gasket twice and torqued it down and it is still leaking horribly. The vehicle is a 95 Pathfinder.
I don't know what to say... I'll assume you have the correct gasket size... have you checked for cracks on the housing and block? Did you clean the gasket contact surfaces completely? Did you add silicone to both sides of the gasket? How much torque are you using?... too tight will split the gasket.

Did you install a new thermostat? Is it the right size?
 

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I'd say you have some imperfections on the housing cover, rust pits or something..I took mine to a wire wheel when i had it off..
 

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Is the thermostat in the right direction? ;)
 
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