is the oil leakage/seapage only into the plug tubes? Or would I have oil escaping out onto the exterior of the valve cover onto the engine/manifold?
In my experience with the vk45de, you will typically see the oil on the exterior of the valve cover if your gasket fails. The tube seals sometimes fail and will let oil into the plug tubes. When the latter happens, there's no cheap or simple fix but to replace the valve cover. Again, not typical, and the valve cover-head seal will go before you have to deal with the tube seals.
What will the car do when this problem becomes critical? Will it be immediate failure and I'll be on the side of the road or will I have ample warning something's not right?
At worst, you ignore the oil leak and run your engine a little low on oil and start a bad chain reaction, but this will only happen if you ignore -> If enough oil seeps thru the valve cover gaskets, it will make it to the exhaust manifold and stink when it's burned.
I would assume the plugs are sealed and the oil would just sit in the tubes?? Or will it be able to penetrate the coil assembly? Maybe a misfire will begin ..?
Oil goes the other way. The space between the head and valve cover will have oil and at pressure it seeps through the tube seals if they have deteriorated. They thus make it past/down the coil pack tubes, but will just pool there since the spark plug has blocked the exit of the tube.
And lastly, whats the cost on replacing the gasket and will the new one do the same?
I have bought sets online at typically 40 bucks per pair. IIRC, oem was about 60 bucks and I would assume the rubber will last just as long as the original leaky one lasted.
But I'd also like to say that the oil consumption was separate from any valve cover gasket maintenance. Even then I don't think vk45s had issues with their valve cover seals.