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'22 Rav4 w/ leaky main seal on front transaxle

3802 Views 31 Replies 13 Participants Last post by  Big Daddy
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 hrs 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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Has anyone on this discussion had resolution on their vehicle leaking?

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 .
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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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.
Been reading through this thread and hoooooly crap what a mess!! I simply cannot fathom the incompetence displayed by this dealer, and it kind of makes me not want to take my RAV4 there even for the complimentary service that I’ve got for the next two years!! I treat my car like it’s my baby. If I got it back from service with any sort of scratches, paint damage, or any kind of scuff mark whatsoever I’d be livid. Thanks for the nightmares! I hope they buy that car back and so you can get a new one. Again, what a terrible dealership.
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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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Well this is a timing thread. My 2020 Rav4 is due for an oil change and I am debating to do it myself or take to the dealer.
My 3 year warranty is up as well. After reading this thread, I am inclined to do myself.

Sorry to folks that are having this issue. I hope mine is ok and thanks for posting so I know to look for it.
I performed an oil change on my '17Rav4 Limited I bought 4/19 coming off lease. It went well. For peace of mind I bought a new plastic housing and put the original one on the shelf.
The articles I read said be sure to replace all seals. The oil filter cartridge had all the needed seals so all fresh. That was Feb 22, 4000 mi ago. Now I will do oil change when weather
in Cleveland is nice. Changing oil and filter cartridge based on time in use. I use spec'd oil for 15k mi and filter cartridge for 15k mi. My doing it keeps me happy. I had a cap style tool to remove the housing and that is best way to do it and not mess up the plastic cap. The cap has a nut and removing it I threaded in the release connector allowing me to drain the oil from the filter cartridge and cap assembly before removing them. Less mess that way. I liked that.
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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.
Is it a Japan, Canada or Kentucky RAV?
Well this is a timing thread. My 2020 Rav4 is due for an oil change and I am debating to do it myself or take to the dealer.
My 3 year warranty is up as well. After reading this thread, I am inclined to do myself.

Sorry to folks that are having this issue. I hope mine is ok and thanks for posting so I know to look for it.
Definitley do it yourself, in states like California dealerships are not allowed to fire lazy employees easily so instead they'll stick them in the lube pit. These are the ones who will use impact wrench to tighten your oil filter, if they even change it at all and strip the drain plug threads, and not change the crush washer.
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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This is just crazy, it just proves the point that sh** dealers are everywhere.
Pity the poor bastard who buys it at auction, wait they will show up here asking how to fix this leaking car, which they brought at auction really cheap,
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".
Are you looking to to buy another Rav4, or moving on to another brand?
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