I had this problem on a 2.5 year old Autocraft battery and I tried about everything, the felt washer, coating with the anti-corrosion gel. Finally I mixed some clear epoxy and coated around the base of the post. That seemed to have fixed the problem. So even though I could not see a crack, that must have been the problem, allowing gas to come up around the post. The battery died shortly after however. After some back and forth, Advance did replace the battery.