Transfer box sump

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Over tightening?
Have you tried sealant?
Rocky mountain have finned sump that is much stiffer, if you're feeling flush.
 
Lay the cover out on a flat surface and check the mating surface. if it's bulged around the bolt holes you need to clean it up till the surface is nice and flat. A file and patience are your friends here. Once done doing that check the mating surface on the T-case and get rid of any burrs or raised areas that will cause the cover not to seat.

RTV both sides, new gasket, and don;t overtighten it.

ajr
 
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