Mysterious oil leak - opinions please...

[Octane]

Originally Posted by friendly_jacek

Interesting. I didn't think there was that much torque going in the RAV4's AWD setup. Why would downshifting put stress on the shaft? I'm concerned as I tow a boat (rarely these days).

IMO, it's not a question of how much torque goes to the transfer case, it's a question of how much torque the plastic composite shaft can take... if the shaft is not made to pull 3500lbs, then they should make it stronger or drop the tow rating!

[BD72055]

I have placed a sheet of cardboard covered in white paper under my car since I brought her home from the dealer on January 23. Dripping oil again and the dealer told me nothing happened while they had the car for almost two days. Sorry, I don't believe it. They must have disturbed something because now the small drops of oil are much larger and are in a different position. I park in the exact same spot in my garage and I circled the oil stains with a Sharpie Marker and added the date of the stain. I am documenting this for the dealer who cannot locate the source of the oil leak. They gave me a loaner car and my RAV4 has the Toyota warranty, so I am not too concerned about how long it's going to take to resolve this problem.

It's definitely not engine oil, smells like gear oil to me, it's a bit foul smelling too. However, in my experience (worked on cars as a hobby since I was 16) the oil appears to be on the thin side where I have seen and used 90W gear oil. The white paper I used on the sheet of cardboard under my RAV4 clearly shows the color, which is nearly transparent, maybe a very slight tan. It appears to be leaking more now too. Since the RAV4 is under warranty, I don't care if the transmission and / or transfer case fails, I have to get this repaired while it's free of charge. I take good care of my cars, don't beat them to death or drive them abusively. I have had two other Toyota's in the past and they were very reliable. As I said in the beginning of this thread, this is a real mystery! Thank you all for your opinions and suggestions. I will post another update in a few days. Time to visit the dealer on Monday morning, only this time I am going to walk in with the oil stained cardboard sheet in my hand. I'll be nice and professional too!

[friendly_jacek]

Originally Posted by BD72055

the oil appears to be on the thin side where I have seen and used 90W gear oil.

Because Toyota used 85W90 and not straight 90 (there is even a sticker to that effect on the transfer case). 90 weight gear oil is similar to 40 weight engine oil regardless, so it isn't that thick.

[SeriousBlack]

Did you check this thread out? Mystery Solved - Left Front Axle Seal Replaced

[BD72055]

Originally Posted by SeriousBlack

Did you check this thread out? Mystery Solved - Left Front Axle Seal Replaced

Thank you, what was the final result? Unless I missed that!

It may be an overfilled transfer case and some of the oil is escaping from the breather vent. The dealer isn't sure, but I am going to use the RAV4 for one full week with paper towels on my garage floor, then I am bringing it back to Toyota for a loaner car so they can figure this out. They have very good about the whole event, very cooperative. It hasn't cost me anything and there is only 37K miles on the car now. I just want it repaired correctly, especially while it's under warranty! She goes back next Monday, 2/4/13. Thank you again for your help and suggestions!

[friendly_jacek]

Originally Posted by SeriousBlack

Did you check this thread out? Mystery Solved - Left Front Axle Seal Replaced

This is off topic as yours leaked ATF.

[SeriousBlack]

Originally Posted by friendly_jacek

This is off topic as yours leaked ATF.

How is it off topic when the topic is "Mysterious oil leak - opinions please..." ?

Good luck OP. After the seal was replaced on my RAV4, the tranny started to go. Hopefully yours will be something different, but at least your covered with your warranty!

[BD72055]

It's been about two weeks and I placed a sheet of cardboard covered with white paper towels under the RAV4. The leak is small, but it's nearly clear in color with a foul smell, like gear oil. I can barely see it on the paper towel, but can feel it's oil. I haven't brought it back to the dealer yet, waiting for better weather. So that's about all I have for now, clear, oily, thin liquid with a gear oil smell. A friend of mine thinks the transfer case is over filled and the excess is coming out of a vent somewhere. Also, You can clearly smell the oil when you step out of the RAV4, whether I park in the garage or if I'm outside somewhere, it's a distinctive odor!

The saga continues...

[BD72055]

A week ago I called the dealer to schedule an oil change and to have them locate & repair this ongoing random oil leak. They traced it down to the transfer case, when they replaced the oil, they found two seals on the filler plug and no seal on the drain plug. It's been a full week now, no oil on the garage floor. I believe they found the leak, hopefully. They also replaced an oxygen sensor, the check engine light came on just before I dropped the RAV4 off for the oil change, great timing. I'm glad I have the 100,000 mile warranty! Thanks for your advice and opinions guys!