NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
22 reportsClear category filter144,000 miles · Jan 15, 2018
Power Train
TRANSFER CASE FAILURE CABIN FILLING WITH ACID SMOKE FROM BEARING FAILURE IN TRANSFER CASE, CAR WAS DRIVEN TO LOCAL GARAGE FOR REPLACEMENT NOT COVERED EVEN THOUGH THERE IS NUMEROUS FAILURES WITH THIS CAR. MAZDA HAS MADE NUMEROUS CHANGES IN THIS DESIGN SO WHY ISNT THERE A RECALL . THIS HAPPENED WHEN MY CAR WAS AT A STOP SIGN.THIS …
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TRANSFER CASE FAILURE CABIN FILLING WITH ACID SMOKE FROM BEARING FAILURE IN TRANSFER CASE, CAR WAS DRIVEN TO LOCAL GARAGE FOR REPLACEMENT NOT COVERED EVEN THOUGH THERE IS NUMEROUS FAILURES WITH THIS CAR. MAZDA HAS MADE NUMEROUS CHANGES IN THIS DESIGN SO WHY ISNT THERE A RECALL . THIS HAPPENED WHEN MY CAR WAS AT A STOP SIGN.THIS IS A COMMON PROBLEM WITH THIS CAR THAT COULD LEAD TO SOMEONE TO PANIC WITH SUCH HORRIBLE SMELLING SMOKE.
NHTSA ODI #11062879
113,400 miles · Nov 16, 2015
Power Train
CAR WAS MAKING GRINDING SOUNDS WHEN THE VEHICLE WAS IN MOTION, ESPECIALLY WHEN I TURNED LEFT/RIGHT AS WELL AS WHEN I WAS STOPPING THE VEHICLE. MOST NOTICEABLE ON CITY STREETS. NEEDED TO REPLACE TRANSFER CASE AND TRANSMISSION.
NHTSA ODI #10790609
77,200 miles · Sep 30, 2015
Power TrainFire
TL* THE CONTACT OWNS A 2010 MAZDA CX-9. WHILE ACCELERATING FROM A TRAFFIC LIGHT, THERE WAS AN ABNORMAL BURNING ODOR COMING FROM THE FRONT OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS NOTIFIED THAT THE TRANSFER CASE HAD A LEAK. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAI…
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TL* THE CONTACT OWNS A 2010 MAZDA CX-9. WHILE ACCELERATING FROM A TRAFFIC LIGHT, THERE WAS AN ABNORMAL BURNING ODOR COMING FROM THE FRONT OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS NOTIFIED THAT THE TRANSFER CASE HAD A LEAK. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 77,200. *CN
NHTSA ODI #10778759
62,593 miles · Oct 26, 2014
Power Train
THIS CAR IS MAINTAINED TO MANUFACTURER'S REQUIREMENTS. SMOKE FILLED THE DRIVERS CABIN, COMING FROM OIL DRIPPING OUT OF THE FAILED POWER TRANSFER CASE, DRIPPING ONTO THE EXHAUST PIPE AND RISING SMOKE INTO THE CABIN. THIS WAS UNSAFE AND THE CAR BECAME UNUSABLE OVER A FEW DAYS. I HAD THE TRANSFER CASE REPAIRED AT A COST OF $13…
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THIS CAR IS MAINTAINED TO MANUFACTURER'S REQUIREMENTS. SMOKE FILLED THE DRIVERS CABIN, COMING FROM OIL DRIPPING OUT OF THE FAILED POWER TRANSFER CASE, DRIPPING ONTO THE EXHAUST PIPE AND RISING SMOKE INTO THE CABIN. THIS WAS UNSAFE AND THE CAR BECAME UNUSABLE OVER A FEW DAYS. I HAD THE TRANSFER CASE REPAIRED AT A COST OF $1395.89, INCLUDING ASSOCIATED COST OF $136.36 FOR A RENTAL VEHICLE REPLACEMENT. I PAID FOR THE REPAIR WITH A PRIVATE EXTENDED WARRANTY, THAT WAS NOT PART OF MAZDA, TO PAY THE REPAIR SHOP. WHEN I APPLIED FOR REIMBURSEMENT UNDER MAZDA'S "SPECIAL SERVICE PROGRAM 92 (2010-2014 CX9 AWD POWER TRANSFER UNIT WARRANTY EXTENSION)", I RECEIVED A LETTER FROM MAZDA NORTH AMERICAN OPERATIONS DENYING ME REIMBURSEMENT, BECAUSE I PAID FOR THE REPAIR USING MY PERSONAL WARRANTY POLICY. SINCE I PURCHASED THIS PERSONAL WARRANTY POLICY, (NOT MAZDA), I BELIEVE I AM ENTITLED TO REIMBURSEMENT FOR THE REPAIR. *TR
NHTSA ODI #10650012
80,801 miles · May 2, 2014
EnginePower Train
WHEN I AM AT A STOP AD START MY VEHICLE ACCELERATES WITHOUT MY ASSISTANCE, THIS HAPPENED ALSO WHILE BACKING UP AND MY FOOT WAS ON THE BRAKE. *TR
NHTSA ODI #10586088
32,760 miles · Oct 2, 2013
Power Train
WHEN I GOT IN THE CAR, THE CHECK TIRE PRESSURE LIGHT WAS ON. STOPPED AT A SERVICE STATION AND HAD THE TIRES CHECKED: ALL WAS FINE. A FEW MILES LATER, THE CAR SUDDENLY MADE A LOUD WHINING NOISE AND THEN LOUD BANGING NOISES AND THE CAR FELT LIKE IT WAS SEIZING AND SHUDDERING. PULLED TO THE SIDE OF THE ROAD, COULDN'T SEE ANYTH…
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WHEN I GOT IN THE CAR, THE CHECK TIRE PRESSURE LIGHT WAS ON. STOPPED AT A SERVICE STATION AND HAD THE TIRES CHECKED: ALL WAS FINE. A FEW MILES LATER, THE CAR SUDDENLY MADE A LOUD WHINING NOISE AND THEN LOUD BANGING NOISES AND THE CAR FELT LIKE IT WAS SEIZING AND SHUDDERING. PULLED TO THE SIDE OF THE ROAD, COULDN'T SEE ANYTHING AMISS UNDER THE HOOD. RE-STARTED THE CAR AND HEADED HOME WITH THE LOUD WHINING NOISE UPON ANY ACCELERATION. I CALLED THE DEALERSHIP THE NEXT DAY AND HAD IT TOWED TO THEM AS I FELT IT WAS UNSAFE TO DRIVE AFTER DOING SOME RESEARCH AND NOTING THE SYMPTOMS WERE SIMILAR TO WHAT OTHER VEHICLE OWNERS HAD REPORTED AS A TRANSFER CASE FAILURE. UPON EXAMINATION THE DEALERSHIP DID SAY IT WAS A TRANSFER CASE FAILURE AND REPLACED IT THAT DAY. I PICKED UP MY CAR TODAY AND SO FAR IT IS DRIVING AND HANDLING FINE. SEVERAL MONTHS PRIOR TO THE VEHICLE FAILURE I HAD NOTED A VERY, VERY FAINT WHINING NOISE WHEN MY SPEED WAS BETWEEN 30 AND 40 MPH. I HAD MY MECHANIC (NOT THE DEALER) TRY TO EXAMINE THE NOISE WHEN HE DID MY ROUTINE 30K MILE SERVICE. THE NOISE WAS SO FAINT HE WAS NOT ABLE TO DETECT IT. HE WASN'T ABLE TO FIND ANY MAZDA SERVICE BULLETINS THAT INDICATED A PROBLEM TO EXAMINE FURTHER. BESIDES THAT FAINT WHINING NOISE THERE WERE NO OTHER INDICATIONS SUCH A DANGEROUS VEHICLE FAILURE WAS GOING TO OCCUR, AND THE CAR CHECKED OUT FINE AT THAT 30K ROUTINE SERVICE. NOT SURE WHY THE CHECK TIRE PRESSURE LIGHT CAME ON IMMEDIATELY PRIOR TO THE FAILURE BUT THE DEALER SAID THEY "RESET" IT WHEN THEY REPLACED THE TRANSFER CASE. THE DEALER WAS VERY PROMPT AND PROFESSIONAL IN THEIR RESPONSE AND TREATED US VERY WELL. BUT I DO FEEL THIS ISSUE IS SO SERIOUS WE SHOULD HAVE RECEIVED NOTICE FROM MAZDA WITH A REQUEST TO GET THE TRANSFER CASE EXAMINED EARLIER. *TR
NHTSA ODI #10546467
76,000 miles · Jun 20, 2013
Power Train
POWER TRANSFER UNIT LEAKING OIL, I MAY LOSE MY 4WD IF THIS IS NOT FIXED SOON. IT WILL COST $1150.00 TO FIX. THERE IS A HORRIBLE SMELL FROM THE LEAK THAT IS COMING INTO THE VEHICLE. I HAVE HAD 4WD VEHICLES FOR YEARS AND NEVER RAN INTO AN INCIDENT WHERE SOMETHING LIKE THIS HAD TO BE REPLACED. DEALER MADE THIS SEEM LIKE THIS IS A…
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POWER TRANSFER UNIT LEAKING OIL, I MAY LOSE MY 4WD IF THIS IS NOT FIXED SOON. IT WILL COST $1150.00 TO FIX. THERE IS A HORRIBLE SMELL FROM THE LEAK THAT IS COMING INTO THE VEHICLE. I HAVE HAD 4WD VEHICLES FOR YEARS AND NEVER RAN INTO AN INCIDENT WHERE SOMETHING LIKE THIS HAD TO BE REPLACED. DEALER MADE THIS SEEM LIKE THIS IS A WEAR AND TEAR ISSUE NOT COVERED UNDER ANY WARRANTY. *TR
NHTSA ODI #10520840
26,000 miles · Jun 7, 2013
Power TrainFire
TL* THE CONTACT OWNS A 2010 MAZDA CX9. THE CONTACT STATED THAT THE VEHICLE EXHIBITED AN OVERPOWERING BURNING ODOR FROM THE VENTS. IN ADDITION, A LOUD KNOCKING SOUND CAME FROM UNDER THE HOOD. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND WAS TOLD THAT THE TRANSFER CASE NEEDED TO BE REPLACED. THE DEALER TEST DROVE THE VEHICLE AND…
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TL* THE CONTACT OWNS A 2010 MAZDA CX9. THE CONTACT STATED THAT THE VEHICLE EXHIBITED AN OVERPOWERING BURNING ODOR FROM THE VENTS. IN ADDITION, A LOUD KNOCKING SOUND CAME FROM UNDER THE HOOD. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND WAS TOLD THAT THE TRANSFER CASE NEEDED TO BE REPLACED. THE DEALER TEST DROVE THE VEHICLE AND THE ENGINE SEIZED. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE AND CURRENT MILEAGES WERE 26,900. *TR
NHTSA ODI #10515703
63,000 miles · May 30, 2013
Power Train
I NOTICED A STRANGE SMELL IN THE VEHICLE. I DROVE A FEW BLOCKS TO HOME (LUCKILY). ENGINE COMPARTMENT WAS SMOKING AS I PULLED IN THE DRIVEWAY. THIS WAS DIAGNOSED BY A MECHANIC AS A CRACKED TRANSFER CASE. LEAKING FLUID FROM THE CASE WAS THE SOURCE OF THE SMOKE; NOT COVERED UNDER WARRANTY BY MAZDA NOR IS THERE A TSB FOR THE PROB…
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I NOTICED A STRANGE SMELL IN THE VEHICLE. I DROVE A FEW BLOCKS TO HOME (LUCKILY). ENGINE COMPARTMENT WAS SMOKING AS I PULLED IN THE DRIVEWAY. THIS WAS DIAGNOSED BY A MECHANIC AS A CRACKED TRANSFER CASE. LEAKING FLUID FROM THE CASE WAS THE SOURCE OF THE SMOKE; NOT COVERED UNDER WARRANTY BY MAZDA NOR IS THERE A TSB FOR THE PROBLEM. A QUICK SEARCH SHOWED THAT TRANSFER CASE PROBLEMS ARE COMMON FOR THIS VEHICLE. THIS COULD HAVE BEEN A SERIOUS ROAD HAZARD. *TR
NHTSA ODI #10514349
29,000 miles · Apr 3, 2013
Power Train
TRANSFER CASE WAS FIRST REPLACED IN JULY 2012 WITH AN OEM PART AND NOW AGAIN 8 MONTHS LATER. LEAKING GEAR OIL, TERRIBLE SMELL COMING INTO COMPARTMENT OF CAR AND ALSO HAD CLUNKING SOUNDS IN FRONT DRIVER SIDE AXEL. *TR
NHTSA ODI #10505508
Official recalls
6Oct 31, 2019
Mazda North American Operations (Mazda) is recalling certain 2007-2012 CX-7, CX-9, and 2009-2012 Maza6 vehicles. These vehicles had their passenger frontal air bag inflators previously replaced under a prior recall using inflators of the same design. The inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence & remedy
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicles until the repair has been performed. Mazda will notify owners, and dealers will replace the front passenger air bag inflator with an alternate one, free of charge. The recall began December 3, 2019. Owners may contact Mazda customer service at 1-800-222-5500, option 4. Mazda's number for this recall is 1317F. Note: This recall supersedes recalls 16V356 and 17V012.
Oct 12, 2018
Mazda North American Operations (Mazda) is recalling certain 2014-2015 Mazda CX-9 vehicles sold, or ever registered in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, unless covered in "Zone A," Mazda is recalling certain 2011-2013 Mazda6, 2011-2012 CX-7, and 2011-2015 CX-9 sold, or ever registered in the states of Arizona, Arkansas, Delaware, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, West Virginia and the District of Columbia, or "Zone B." Additionally, unless covered in Zone A or Zone B, Mazda is recalling certain 2010-2013 Mazda6, 2010-2012 CX-7, and 2010-2015 CX-9 vehicles ever registered in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming or "Zone C." These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may explode due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence & remedy
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Mazda will notify owners, and dealers will replace the front passenger air bag inflator with an alternate inflator, free of charge. The recall began November 9, 2018. Owners may contact Mazda customer service at 1-800-222-5500, Option 4. Mazda's number for this recall is 1317F.
Jan 9, 2018
Mazda North American Operations (Mazda) is recalling certain 2013 Mazda6 and CX-9 vehicles sold, or ever registered in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, unless covered in "Zone A," Mazda is recalling certain 2010 Mazda6, CX-7 and CX-9 vehicles sold, or ever registered in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." Additionally, unless covered in Zone A or Zone B, Mazda is recalling certain 2009 Mazda6, CX-7, and CX-9 vehicles ever registered in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming or "Zone C." These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may explode due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence & remedy
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Mazda will notify owners, and dealers will replace the front passenger air bag inflator with an alternate inflator, free of charge. The recall began March 2, 2018. Owners may contact Mazda customer service at 1-800-222-5500. Mazda's number for this recall is 1317F.
Jun 29, 2017
Mazda North America Operations (Mazda) is recalling certain 2009-2011 Mazda6, and 2007-2011 CX-7 and CX-9 vehicles. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence & remedy
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicles until the remedy is performed. Mazda will notify owners, and dealers will replace the passenger frontal air bag inflator with an alternate inflator, free of charge. The recall began on August 30, 2017. Owners may contact Mazda customer service at 1-800-222-5500. Mazda's number for this recall is 1317F. Note: This recall supersedes recall 16V356 and all vehicles that were not remedied under that campaign are now covered by this one.
Jul 20, 2015
Mazda North American Operations (Mazda) is recalling certain model year 2007-2014 CX-9 vehicles manufactured October 24, 2006, to December 28, 2013. The affected vehicles have front suspension ball joints that may corrode from water leaking into the fitting.
Consequence & remedy
Consequence: Over time, the ball joint corrosion may result in the front lower control arm separating from the ball joint, causing a loss of steering control and increasing the risk of a crash.
Remedy: Mazda will notify owners, and dealers will replace both the left and right lower control arms, free of charge. The recall began on September 14, 2015. The recall will begin with model year 2007-2009 vehicles registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, Washington D.C., West Virginia, and Wisconsin. The second phase will be for model year 2010-2014 vehicles in the same states. Finally, all remaining vehicles will be remedied. Owners may contact Mazda customer service at 1-800-222-5500. Mazda's number for this recall is 8515G.
Additional source detail variants (2)
Suspension:front:control Arm:lower Ball Joint
Mazda North American Operations (Mazda) is recalling certain model year 2007-2014 CX-9 vehicles manufactured October 24, 2006, to December 28, 2013. The affected vehicles have front suspension ball joints that may corrode from water leaking into the fitting.
Consequence: Over time, the ball joint corrosion may result in the front lower control arm separating from the ball joint, causing a loss of steering control and increasing the risk of a crash.
Remedy: Mazda will notify owners, and dealers will replace both the left and right lower control arms, free of charge. The recall began on September 14, 2015. The recall will begin with model year 2007-2009 vehicles registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, Washington D.C., West Virginia, and Wisconsin. The second phase will be for model year 2010-2014 vehicles in the same states. Finally, all remaining vehicles will be remedied. Owners may contact Mazda customer service at 1-800-222-5500. Mazda's number for this recall is 8515G.
Suspension:front:control Arm:lower Arm
Mazda North American Operations (Mazda) is recalling certain model year 2007-2014 CX-9 vehicles manufactured October 24, 2006, to December 28, 2013. The affected vehicles have front suspension ball joints that may corrode from water leaking into the fitting.
Consequence: Over time, the ball joint corrosion may result in the front lower control arm separating from the ball joint, causing a loss of steering control and increasing the risk of a crash.
Remedy: Mazda will notify owners, and dealers will replace both the left and right lower control arms, free of charge. The recall began on September 14, 2015. The recall will begin with model year 2007-2009 vehicles registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, Washington D.C., West Virginia, and Wisconsin. The second phase will be for model year 2010-2014 vehicles in the same states. Finally, all remaining vehicles will be remedied. Owners may contact Mazda customer service at 1-800-222-5500. Mazda's number for this recall is 8515G.
Feb 19, 2010
MAZDA IS RECALLING CERTAIN MODEL YEAR 2010 CX-9 VEHICLES EQUIPPED WITH ELECTRICALLY HEATED FRONT SEATS. THERE IS A POSSIBILITY UNDER EXTREMELY COLD CONDITIONS FOR THE SEAT HEATER CONTROL CIRCUIT TO OVERHEAT AND FAIL DUE TO INSUFFICIENT ELECTRICAL GROUNDING.
Consequence & remedy
Consequence: THIS MAY CAUSE BURN DAMAGE OF THE SEAT CUSHION SURFACE, OR A RISK OF SMOKE/FIRE.
Remedy: DEALERS WILL INSTALL AN ADDITIONAL GROUND HARNESS ON THE SEAT HEATER CONTROL SYSTEM. THE SEAT HEATER CONTROL CIRCUIT WILL BE REPLACED IF NECESSARY AND/OR THE SEAT WILL BE REPAIRED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MARCH 9, 2010. OWNERS MAY CONTACT MAZDA AT 1-800-222-5500.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3PE19006 · Inadvertent Curtain Air Bag Deployment
Opened May 2, 2019 · Closed Jan 15, 2021
Status: closed (inferred from source dates) · Air Bags; Air Bags:side/window; Air Bags:side/window:curtain
The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE19-006) on May 2, 2019 to investigate two Vehicle Owner Questionnaires (VOQs) and Early Warning Reporting data related to allegations of inadvertent deployment (IAD) of side curtain airbags in Model Year (MY) 2010 through 2013 Mazda CX-9 vehicles. ODI sent an Information Request (IR) to Mazda North America Operations, LLC. to gather information about the alleged defect in the subject vehicles. In the 20 months since opening the PE, ODI has received three additional VOQs. To date, there have been a total of 11 IAD incidents within the identified population of 104,360 vehicles. Of the 11 incidents, no serious injuries were reported. The last known incident occurred in December 2020.Mazda's response to ODI's IR letter identified the root cause as a manufacturing issue of the Bosch SMG076 Roll Rate Sensor within the Restraint Control Module (RCM). During the manufacturing calibration process, small particles may be generated that could affect roll sensor capacitance, which could lead to a loss of curtain airbag protection or an erroneous deployment command. On November 19, 2012, a revised Roll Rate Sensor calibration process was launched, establishing a clean point for the issue. In its responses to ODI, Mazda has assessed the condition as a low risk to motor vehicle safety, with low incident frequency not warranting action. Any RCM data indicating a malfunctioning Roll Rate Sensor will result in the illumination of the airbag warning light. In the event of an erroneous curtain airbag deployment, there is no contact with properly seated occupants. Additionally, the condition is not affected by deterioration or wear, and known incidents established a random pattern of occurrence.During the investigation, ODI examined the injury risk to vehicle occupants from curtain airbag deployments. It was determined that the subject vehicles do not pose a substantial risk to out of position occupants, as testing data falls within Technical Working Group (TWG) reference values. Modeling simulation based on data provided by Mazda for properly seated occupants during static and dynamic airbag deployments indicated sufficient head clearance and no risk of brain injury. ODI analysis reveals that inadvertent deployment incident rates of curtain airbags in the subject vehicles are low through approximately ten years in service. Incident frequency does not meet values warranting recall action, but rather align closely with baseline frequency of general inadvertent deployments which are known to occur in rare driving conditions. Additionally, warranty analysis of RCM failures resulting in a loss of curtain airbag protection revealed low claim rates.Based on the analysis conducted, this investigation has been closed. The closing of this investigation does not foreclose the Agency from taking further action, if warranted, or the potential for a future finding that a safety-related defect exists, based upon additional information the Agency may receive.The five ODI complaints cited above can be reviewed at NHTSA.gov under the following identification numbers: 10905492, 11165925, 11270089, 11310044, 11385219.
Additional source detail variants (3)
Air Bags
The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE19-006) on May 2, 2019 to investigate two Vehicle Owner Questionnaires (VOQs) and Early Warning Reporting data related to allegations of inadvertent deployment (IAD) of side curtain airbags in Model Year (MY) 2010 through 2013 Mazda CX-9 vehicles. ODI sent an Information Request (IR) to Mazda North America Operations, LLC. to gather information about the alleged defect in the subject vehicles. In the 20 months since opening the PE, ODI has received three additional VOQs. To date, there have been a total of 11 IAD incidents within the identified population of 104,360 vehicles. Of the 11 incidents, no serious injuries were reported. The last known incident occurred in December 2020.Mazda's response to ODI's IR letter identified the root cause as a manufacturing issue of the Bosch SMG076 Roll Rate Sensor within the Restraint Control Module (RCM). During the manufacturing calibration process, small particles may be generated that could affect roll sensor capacitance, which could lead to a loss of curtain airbag protection or an erroneous deployment command. On November 19, 2012, a revised Roll Rate Sensor calibration process was launched, establishing a clean point for the issue. In its responses to ODI, Mazda has assessed the condition as a low risk to motor vehicle safety, with low incident frequency not warranting action. Any RCM data indicating a malfunctioning Roll Rate Sensor will result in the illumination of the airbag warning light. In the event of an erroneous curtain airbag deployment, there is no contact with properly seated occupants. Additionally, the condition is not affected by deterioration or wear, and known incidents established a random pattern of occurrence.During the investigation, ODI examined the injury risk to vehicle occupants from curtain airbag deployments. It was determined that the subject vehicles do not pose a substantial risk to out of position occupants, as testing data falls within Technical Working Group (TWG) reference values. Modeling simulation based on data provided by Mazda for properly seated occupants during static and dynamic airbag deployments indicated sufficient head clearance and no risk of brain injury. ODI analysis reveals that inadvertent deployment incident rates of curtain airbags in the subject vehicles are low through approximately ten years in service. Incident frequency does not meet values warranting recall action, but rather align closely with baseline frequency of general inadvertent deployments which are known to occur in rare driving conditions. Additionally, warranty analysis of RCM failures resulting in a loss of curtain airbag protection revealed low claim rates.Based on the analysis conducted, this investigation has been closed. The closing of this investigation does not foreclose the Agency from taking further action, if warranted, or the potential for a future finding that a safety-related defect exists, based upon additional information the Agency may receive.The five ODI complaints cited above can be reviewed at NHTSA.gov under the following identification numbers: 10905492, 11165925, 11270089, 11310044, 11385219.
Air Bags:side/window:curtain
The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE19-006) on May 2, 2019 to investigate two Vehicle Owner Questionnaires (VOQs) and Early Warning Reporting data related to allegations of inadvertent deployment (IAD) of side curtain airbags in Model Year (MY) 2010 through 2013 Mazda CX-9 vehicles. ODI sent an Information Request (IR) to Mazda North America Operations, LLC. to gather information about the alleged defect in the subject vehicles. In the 20 months since opening the PE, ODI has received three additional VOQs. To date, there have been a total of 11 IAD incidents within the identified population of 104,360 vehicles. Of the 11 incidents, no serious injuries were reported. The last known incident occurred in December 2020.Mazda's response to ODI's IR letter identified the root cause as a manufacturing issue of the Bosch SMG076 Roll Rate Sensor within the Restraint Control Module (RCM). During the manufacturing calibration process, small particles may be generated that could affect roll sensor capacitance, which could lead to a loss of curtain airbag protection or an erroneous deployment command. On November 19, 2012, a revised Roll Rate Sensor calibration process was launched, establishing a clean point for the issue. In its responses to ODI, Mazda has assessed the condition as a low risk to motor vehicle safety, with low incident frequency not warranting action. Any RCM data indicating a malfunctioning Roll Rate Sensor will result in the illumination of the airbag warning light. In the event of an erroneous curtain airbag deployment, there is no contact with properly seated occupants. Additionally, the condition is not affected by deterioration or wear, and known incidents established a random pattern of occurrence.During the investigation, ODI examined the injury risk to vehicle occupants from curtain airbag deployments. It was determined that the subject vehicles do not pose a substantial risk to out of position occupants, as testing data falls within Technical Working Group (TWG) reference values. Modeling simulation based on data provided by Mazda for properly seated occupants during static and dynamic airbag deployments indicated sufficient head clearance and no risk of brain injury. ODI analysis reveals that inadvertent deployment incident rates of curtain airbags in the subject vehicles are low through approximately ten years in service. Incident frequency does not meet values warranting recall action, but rather align closely with baseline frequency of general inadvertent deployments which are known to occur in rare driving conditions. Additionally, warranty analysis of RCM failures resulting in a loss of curtain airbag protection revealed low claim rates.Based on the analysis conducted, this investigation has been closed. The closing of this investigation does not foreclose the Agency from taking further action, if warranted, or the potential for a future finding that a safety-related defect exists, based upon additional information the Agency may receive.The five ODI complaints cited above can be reviewed at NHTSA.gov under the following identification numbers: 10905492, 11165925, 11270089, 11310044, 11385219.
Air Bags:side/window
The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE19-006) on May 2, 2019 to investigate two Vehicle Owner Questionnaires (VOQs) and Early Warning Reporting data related to allegations of inadvertent deployment (IAD) of side curtain airbags in Model Year (MY) 2010 through 2013 Mazda CX-9 vehicles. ODI sent an Information Request (IR) to Mazda North America Operations, LLC. to gather information about the alleged defect in the subject vehicles. In the 20 months since opening the PE, ODI has received three additional VOQs. To date, there have been a total of 11 IAD incidents within the identified population of 104,360 vehicles. Of the 11 incidents, no serious injuries were reported. The last known incident occurred in December 2020.Mazda's response to ODI's IR letter identified the root cause as a manufacturing issue of the Bosch SMG076 Roll Rate Sensor within the Restraint Control Module (RCM). During the manufacturing calibration process, small particles may be generated that could affect roll sensor capacitance, which could lead to a loss of curtain airbag protection or an erroneous deployment command. On November 19, 2012, a revised Roll Rate Sensor calibration process was launched, establishing a clean point for the issue. In its responses to ODI, Mazda has assessed the condition as a low risk to motor vehicle safety, with low incident frequency not warranting action. Any RCM data indicating a malfunctioning Roll Rate Sensor will result in the illumination of the airbag warning light. In the event of an erroneous curtain airbag deployment, there is no contact with properly seated occupants. Additionally, the condition is not affected by deterioration or wear, and known incidents established a random pattern of occurrence.During the investigation, ODI examined the injury risk to vehicle occupants from curtain airbag deployments. It was determined that the subject vehicles do not pose a substantial risk to out of position occupants, as testing data falls within Technical Working Group (TWG) reference values. Modeling simulation based on data provided by Mazda for properly seated occupants during static and dynamic airbag deployments indicated sufficient head clearance and no risk of brain injury. ODI analysis reveals that inadvertent deployment incident rates of curtain airbags in the subject vehicles are low through approximately ten years in service. Incident frequency does not meet values warranting recall action, but rather align closely with baseline frequency of general inadvertent deployments which are known to occur in rare driving conditions. Additionally, warranty analysis of RCM failures resulting in a loss of curtain airbag protection revealed low claim rates.Based on the analysis conducted, this investigation has been closed. The closing of this investigation does not foreclose the Agency from taking further action, if warranted, or the potential for a future finding that a safety-related defect exists, based upon additional information the Agency may receive.The five ODI complaints cited above can be reviewed at NHTSA.gov under the following identification numbers: 10905492, 11165925, 11270089, 11310044, 11385219.
PE15022 · Lower Ball Joint Separation
Opened Jun 9, 2015 · Closed Aug 20, 2015
Status: closed (inferred from source dates) · Suspension:front:control Arm:lower Ball Joint
In an July 7,2015 letter to NHTSA, Mazda identified a safety defect that could result in lower ball joint separation in approximately 193,484 model year (MY) 2007 through 2014 Mazda CX-9 vehicles (NHTSA Recall No. 15V-451,Mazda 8515G).Mazda indicated that damage to the ball joint boot may allow water to enter the front suspension ball joint fitting during use which may result in premature ball joint wear and a progressively looser joint.In January 2014, Mazda implemented redesigned lower control arms in production vehicles to improve the durability of the lower ball joints.The redesign involved changing the shape of the top surface of the ball joint boot cover and adding a suspension plate to the undersurface of the knuckle.Mazda's recall will replace the defect lower control arms with the redesigned parts.ODI's analysis of information collected during PE15-022 identified a total of 62 ball joint separation incidents, including 34 identified in ODI complaints and 31 identified in Mazda complaints and field reports (3 of the Mazda records involve vehicles/incidents that were also reported to ODI).When Mazda's design change was implemented, most of the field experience related to lower ball joints involved complaints of noise and premature wear-out.Only 1 of the ODI and 6 of the additional Mazda separation complaints identified in ODI's analysis were reported prior to January 2014.Significant increases in the number and trend in separation complaints were observed in 2015, when 30 of the ODI complaints and 16 of the additional Mazda complaints were reported.The report trend appears to be accelerating, with 29 of the reports received after ODI opened PE15-022 on June 9, 2015.There has been one crash reported to ODI related to the alleged defect (VOQ 10746510). This investigation is closed based on Mazda's recall.The 34 VOQs associated with this investigation are: 10747358, 10746510, 10744897, 10743509, 10736229, 10735938, 10734763, 10734302, 10734290, 10733813, 10732578, 10732217, 10732154, 10731850, 10730736, 10730280, 10730143, 10730114, 10726622, 10726480 10726448, 10726168, 10725839, 10725567, 10725488, 10725427, 10725390, 10717510, 10714469, 10695142, 10668978, 10648429, 10640541, 10546535
PE14005 · Brake Booster Failure
Opened Feb 10, 2014 · Closed Jun 26, 2014
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:power Assist
In March 2014, Mazda Motor Corporation (Mazda) initiated Special Service Program SSP93 to extend the warranty coverage for a specific brake booster fault condition on model year (MY) 2007-2013 Mazda CX-9 vehicles.According to Mazda's dealer communication for SSP93, the subject vehicles may exhibit a condition were the brake pedal is harder than usual to depress. Complainants report hearing air leakage (hissing) from the driver-side foot area during braking.The Mazda program extends the warranty coverage for repairing this condition to unlimited time and mileage for repairs performed between March 31, 2014 and March 31, 2015 and to 7 years or 90,000 miles for repairs performed after March 31, 2015.In its response to the Office of Defects Investigation's (ODI) information request letter for PE14-005, Mazda identified a problem with booster diaphragms developing tears near the outer seal/circumference that can result in noise and degraded booster performance as the tears grow in length (Figures 1-3).The tears allow leakage from the ambient to the vacuum sides of the diaphragm that reduces the differential pressure across the diaphragm and produces a hissing noise after the tears have reached 10-12 mm in length.The problem was caused by wear of the mold used for the diaphragm forming process, which resulted in increased thickness and stress in the bending area of the diaphragm.Continuous operation in environments with high ambient temperatures accelerates the hardening of the diaphragm material, further increasing the stress in the bending area and contributing to tear initiation and propagation rate.Analysis of failure data indicates that the tool wear condition affected vehicles produced after June 2010 and operated in hot states (Figures 4-6).In February 2013 the supplier introduced a new mold and changes to the diaphragm thickness monitoring process to correct the condition in production vehicles.Analysis of complaint and supplier test data indicates that the diaphragm tear condition is a progressive failure that develops slowly over time.Smaller tears have little effect on system performance.As the tear continues to grow, the effects become more evident.The hard pedal and increased effort are experienced during initial pedal application, but are diminished as the pedal is pressed further by the driver and the tear is partially sealed by the outer wall of the booster.This change from a hard to a soft pedal feel is described by some drivers as a spongy pedal.For tear lengths that were observed in warranty return parts, testing demonstrated that most booster performance can be recovered with increasing pedal apply speed and apply force.None of the tears measured in return parts grew large enough to cause a complete loss of brake booster function. The booster diaphragm tear condition results in partial reduction in booster function that progresses gradually over time with audible and pedal feel symptoms available to the driver.The condition does not result in a sudden loss of power braking assist.The effects are evident during initial pedal apply and are reduced by increased pedal apply force and rate.ODI has not identified any accidents associated with the booster diaphragm tear condition in the subject vehicles.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect and take further action in the future if warranted.VOQs (24) associated with this investigation:10482005, 10486941, 1048793
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