I have a Rowenta and exactly the same thing - it appears that mine is leaking from where the top of the handle joins the iron - there is a crevas there and the water seems to be coming out of it - and if I don't fill it beyond that point it behaves itself. I asked my husband to try putting a dob of silicone in that spot and see if it stops it - he insists I send it back - but if that would solve the problem, I otherwise would like the iron. I also find that I need to lock that steam thing open - otherwise it keeps creaping back down to where it does not steam anymore. Granted I would never buy another one - Black & Decker from good ol' Wal-mart would be my next choice - though I do have a Proctor-Silex that steams great and all, but I have it on high (all the time) and I don't have to worry about burning anything because it doesn't get hot enough. Also so many irons out there have the safety/auto shut off - I would think that would drive me nuts if I am on a sewing spree. :-)
Marysewfun