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2022 RAV4 Adventure
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Hello all. Been lurking for a number of months and finally decided to join - mostly prompted by my experience with my 5 month old XLE.

At 8500 km I found a leak beneath the car, that has subsequently been diagnosed by the dealer as a main seal leak of the front transaxle (output side).

Most frustrating is that 72 before I found the leak, the Rav4 was in for Service 1, and was given an 'all good' by the dealer. A few days later, like many new owners of these modern Toyota engines, I did my first oil change. The moment I got under the car I noticed streaks of fluid on the underside of the oil filter/drain plug panel. After a quick inspection I determined that neither the drain plug nor the filter were the source of the leak.

As frustrating as it is to have a new Toyota with this sort of problem, more frustrating is the fact that having paid for Toyota's ESP, the technician/s who had the car on the hoist three days earlier did not have the presence of mind to raise a red flag when streaks of fluid were clearly present (on a new car). Imagine the mess and mechanical problems that could have been present if I did not change my oil when I did, and had waited another 8 thousand km to go in for Service 2 (which as you already know is the first oil change). Needless to say, the service work to repair the leak is being done by another dealer.

Curious, has anyone else experienced this sort of issue on a new Toyota?
What about dealing with incompetence at some dealer service centres?

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Not a happy camper right now. My 2022 RAV4 Adventure is at the dealership (not where I purchased it), for the same issue. Took delivery on 9/19, in the shop on 9/28 with just over 300 miles on it. Noticed a puddle of gear oil on the garage floor and a trail where I turn in the driveway. Dealer says they have not seen this before. Search RAV4 Oil Leak on youtube. Several 2021 and 2022 RAV4s with the same issue.
 

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2022 RAV4 Adventure
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Not a happy camper right now. My 2022 RAV4 Adventure is at the dealership (not where I purchased it), for the same issue. Took delivery on 9/19, in the shop on 9/28 with just over 300 miles on it. Noticed a puddle of gear oil on the garage floor and a trail where I turn in the driveway. Dealer says they have not seen this before. Search RAV4 Oil Leak on youtube. Several 2021 and 2022 RAV4s with the same issue.
Update: 10/18/22
Went to pick up the RAV4 yesterday as it was finished. Asked them to bring the vehicle in so I could do a walk-around.
Vehicle was not cleaned, had dirt and what looks like oil streaks on the front passenger fender. Needs a good cleaning. Found 2 scratches through the paint. 1) on the front grill surround as it rolls up toward the hood. 2) under the hood just right of center, scratches down to bare metal. Also found broken glass in the rear driver side floor. Luckily the all-weather mat was installed and caught most of it. I can see where something hit the doorsill and splashed to the inside, landing in the mat.
Needless to say the RAV4 is still at the dealership as I did not accept it.
 

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2022 RAV4 Adventure
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Update #2: 10/24/22
Drove past the dealer on Saturday, just to see where they were at with the repairs (see previous replies). My Rav4 was parked outside and it looked like it was finished. Asked the service advisor about it and he said he was waiting on the paperwork. I asked if I could open the car and give it a once over, which he approved. Everything looks good. Paint was repaired in both locations. Can't tell there was anything wrong. Looks like it was detailed as well. Then I looked under the car, just being curious, as it was in the shop for the gear oil leak. IT'S STILL LEAKING GEAR OIL! There was a about a 2" to 3" circle of gear oil on the ground and oil drips on the bottom of the car. I reached underneath and touched the drip and it ran down my finger into my hand. I went in, told the service advisor and showed him the oil on my hand.
He wrote a note, to give to the service manager this morning. Waiting on a call.
 

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2022 RAV4 Adventure
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Update #3 11/15/22
A lot has happened, none of it good. Going to try and keep this short and to the point.
10/24 - No returned call. Had to call Svc Dept to get an update. Was told "I had to give them time to fix the vehicle". I explained the leak was supposed to have already been fixed and as of 10/22, they were just waiting on paperwork. The car was still leaking.
10/27 - Got a call that the car was ready. They said it was just residual oil, and all was cleaned up now. Picked up car.
10/28 - Drove car to work, checked underneath, gear oil streaks on bottom of car. It's STILL LEAKING! Back to Toyota Svc for another look. Was asked to bring the car back Monday as the Svc Mgr was out.
10/31 - Car stayed in my garage over the weekend. Gear oil on floor of garage Took it in and told the Svc Mgr that I wanted to see under the vehicle went they get it on the lift. When on the lift, they saw there was gear oil on the bottom. They removed the plastic cover and found gear oil leaking from the same location as before. They had to remove the engine and change the seals between the transmission and the transfer case the first time. They wiped it off and within a minute, it was oozing out again.
11/2 - Got a notification from the Toyota app that the car was driven 63 miles on 11/1. (3 separate 21 mile trips). To see if it would continue leaking between trips apparently.
11/3 - Drove to Toyota to see what they figured out after all the miles. Master Tech was in the Svc advisor area, so I asked him. He said that the FST Rep from Corporate told him that it was designed to leak as it was an "oil slinger". I called BS on that. MT did as well. He said the Rep was supposed to come down but did not make it. The Master Tech said he inspected everything and it looked ok, but no reason as to why it was still leaking.
11/10 - Toyota called and said a Rep would be down next week.
11/14 - Toyota called and said the Rep would not be down and they were told to replace the transfer case. Svc Mgr told me he would be changing everything right of the transmission.
11/15 - Looking over photos that I took, noticed paint and body sealant scraped off the under of the vehicle, down to bare metal. I'm guessing when they pulled the engine the first time. Sent photo to Toyota. Waiting on a call.
 

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2022 RAV4 Adventure
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Turns out the dealer was sloppy and did not clean out the transmission bell housing during installation of the torque converter ,,, they washed the area ,,, I have not had a leak since . All is good .
My issue is still ongoing. They have had the vehicle for almost 4 months. Supposedly the leak is fixed, changed out transfer case, but they had damaged the body and paint on 3 different occasions during repairs. During the last of those repairs, a parts rack fell over onto the rear passenger door and window. They never called to let us know. We received notifications on the Toyota App that there was all kinds of activity on the vehicle, I called and was given the run-around, so I drove up there. They apparently were not going to tell me and just try to fix it. That door and window was repaired and put back together a couple days ago. The car is ready for pickup today.
Good news is that Toyota Corporate has decided to offer a repurchase of the vehicle under the Lemon Law. Its been about 3 weeks since I sent them the info they requested. Its been all quiet since. Hopefully soon.
 

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2022 RAV4 Adventure
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Update: Picked up the RAV4 on 1/19. Was told the rattling issue was a bolt missing on the brake caliper.???
There are still issues with the body work and alignment on the rear passenger door. I asked about getting it fixed and they stated "if we decide to keep the car after the offer to repurchase from Toyota Corporate, they will make it right". We are not keeping this RAV4, they can wholesale it or whatever they do. The new Title will have to show "Lemon Buyback" on it, from what I've read.
I asked for paperwork on the mechanical repairs and body shop repairs. Was told that it was no charge, so no paperwork was needed. Nope, I needed documentation showing what was done. I have the mechanical work order showing transfer case replacement. Still waiting for the body shop work order(s).
 

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2022 RAV4 Adventure
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Update: Picked up the RAV4 on 1/19. Was told the rattling issue was a bolt missing on the brake caliper.???
There are still issues with the body work and alignment on the rear passenger door. I asked about getting it fixed and they stated "if we decide to keep the car after the offer to repurchase from Toyota Corporate, they will make it right". We are not keeping this RAV4, they can wholesale it or whatever they do. The new Title will have to show "Lemon Buyback" on it, from what I've read.
I asked for paperwork on the mechanical repairs and body shop repairs. Was told that it was no charge, so no paperwork was needed. Nope, I needed documentation showing what was done. I have the mechanical work order showing transfer case replacement. Still waiting for the body shop work order(s).
It's finally over. The RAV4 is gone. Toyota has repurchased the vehicle. I got all my money back with interest.
Final repair tally:
Engine removed 3 times
- 2 for seal replacement.
-1 for transfer case replacement. Still leaks.
Spot painted in 5 locations at different times, that I know of:
  • front grill surround.
  • hood top and underside.
  • front right passenger door.
  • underbody at lifting point with seam sealer replacement where car slid off hoist due to improper placement.
  • rear passenger door w/glass replacement as well.

The title is being Branded as a Lemon Buyback.
The person that accepted the put a sticker on the windshield "To be sold at auction".
 
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