2009 Mazda MAZDA6

Structure

Mazda North American Operations (Mazda) is recalling certain 2009-2010 Mazda Mazda6 vehicles sold, or ever 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, West Virginia, Wisconsin and the District of Columbia. The front cross member may corrode after exposure to road salt.

Consequence: Corrosion may weaken the mounting point for the passenger side lower control arm, unexpectedly changing the steering alignment and increasing the risk of a crash.

Remedy: Mazda will notify owners, and dealers will inspect the cross member and either install a side member and drain hose and apply wax to protect from rust, or install a drain hose and an improved front cross member, free of charge. The recall began March 18, 2019. Owners may contact Mazda customer service at 1-800-222-5500 Option 4. Mazda's number for this recall is 2818I.

Suspension:front:control Arm

Mazda North American Operations (Mazda) is recalling certain 2009-2010 Mazda Mazda6 vehicles sold, or ever 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, West Virginia, Wisconsin and the District of Columbia. The front cross member may corrode after exposure to road salt.

Consequence: Corrosion may weaken the mounting point for the passenger side lower control arm, unexpectedly changing the steering alignment and increasing the risk of a crash.

Remedy: Mazda will notify owners, and dealers will inspect the cross member and either install a side member and drain hose and apply wax to protect from rust, or install a drain hose and an improved front cross member, free of charge. The recall began March 18, 2019. Owners may contact Mazda customer service at 1-800-222-5500 Option 4. Mazda's number for this recall is 2818I.

Air Bags:frontal:sensor/control MODULE-INACTIVE

Mazda North American Operations (Mazda) is recalling certain model year 2009-2010 Mazda6 vehicles manufactured February 4, 2008, to December 3, 2009. The protective coating may not have been properly applied to the air bag control unit (ACU) and, as a result, moisture may damage the unit causing it to malfunction.

Consequence: Failure of the ACU would illuminate the air bag warning light and prevent the air bags from deploying in the event of a crash, increasing the risk of injury.

Remedy: Mazda dealers will replace the ACU, free of charge, however parts are not currently available. The recall began June 2017. Owners may contact Mazda customer service at 1-800-222-5500. Mazda's number for this recall is 9816H.

Air Bags

Mazda North American Operations (Mazda) is recalling certain model year 2009-2010 Mazda6 vehicles manufactured February 4, 2008, to December 3, 2009. The protective coating may not have been properly applied to the air bag control unit (ACU) and, as a result, moisture may damage the unit causing it to malfunction.

Consequence: Failure of the ACU would illuminate the air bag warning light and prevent the air bags from deploying in the event of a crash, increasing the risk of injury.

Remedy: Mazda dealers will replace the ACU, free of charge, however parts are not currently available. The recall began June 2017. Owners may contact Mazda customer service at 1-800-222-5500. Mazda's number for this recall is 9816H.

Suspension:front

In a letter dated September 14, 2018, Mazda North American Operations (Mazda) notified the National Highway Traffic Safety Administration (NHTSA) of a defect in the front subframe assemblies of model year (MY) 2009 through 2010 Mazda6 vehicles in certain states with high road salt use in winter months (Recall 18V-631). The recall covers approximately 48,814 vehicles that were sold or ever registered in the following states and District of Columbia:Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. Mazda indicated that the recalled vehicles may have insufficient paint coating on the front cross member, which after continuous use in salt states may cause premature corrosion of the cross member. As the corrosion progresses over time, the structural integrity of the mounting point at the passenger side of the lower control arm may deteriorate and cause the steering alignment to change. If the steering alignment changes significantly while the vehicle is in motion this may increase the risk of a vehicle crash.ODI's analysis of complaints it has received from the public (VOQ's) and Mazda complaint data submitted in response to the information request letter for PE18-006 identified a total of 53 non-duplicative reports alleging incidents in which front cross-member corrosion had progressed to the stage of complete or partial separation of the subject steering or suspension components and another 98 reports alleging premature and/or excessive corrosion of the subject components with no separation. Mazda's recall will inspect the subframe and apply structural reinforcements, anti-corrosive wax and an AC drain tube free of charge. In cases of excessive corrosion, the subframe will be replaced free of charge.All 53 complaints alleging complete or partial separations involved vehicles that will be covered under Mazda's recall, resulting in a failure rate of 108.6 reports per 100,000 vehicles (R/100k) in the recalled population. When all complaints are analyzed by region, 150 involve vehicles included in Mazda's recall (307.3 R/100k) and just 1 involved a MY 2009 through 2010 Mazda6 vehicle not included in 18V-631 (2.8 R/100k). The field data indicate that Mazda's recall adequately covers vehicles with a risk of experiencing premature corrosion-related failure of the subject steering and suspension components in the subject vehicles. Based on Mazda's safety recall, this investigation is closed.The following VOQs allege loss or compromised steering control while vehicle was in motion:11115277, 11115790, 11128449, 10706604, 10846298, 10899584, 11019306, 11033821, 11048014, 11074634, 11078734, 11080014, 11083781, 11090944, 11091913, 11098279, 11101718, 11102209, 11102796, 11110606, 11110773, 11112830, 11113461, 11113963, 11114039, 11114567, 11114939, 11115303, 11119368, 11119423, 11121341, 11123997, 11124647, 11128648, 11128774, 11130281, 11132046, 11133295, 11133511, 11138829, 11139187, 11139486The following VOQs allege subframe corrosion detection prior to subframe failure:11141172, 11131161, 11129747, 11129349, 11129185, 11128591, 11128223, 11124644, 11122948, 11120047, 11119752, 11119362, 11118786, 11118242, 11115432, 11114568, 11114477, 11114061, 11105334, 11104096, 11103756, 11103724, 11101659, 11100420, 11099962, 11097874, 11084411, 11081783, 11034064, 11025276, 10956316Some VOQs have been omitted from this list due to duplicate VOQ submission between ODI records and Mazda records.

Suspension

In a letter dated September 14, 2018, Mazda North American Operations (Mazda) notified the National Highway Traffic Safety Administration (NHTSA) of a defect in the front subframe assemblies of model year (MY) 2009 through 2010 Mazda6 vehicles in certain states with high road salt use in winter months (Recall 18V-631). The recall covers approximately 48,814 vehicles that were sold or ever registered in the following states and District of Columbia:Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. Mazda indicated that the recalled vehicles may have insufficient paint coating on the front cross member, which after continuous use in salt states may cause premature corrosion of the cross member. As the corrosion progresses over time, the structural integrity of the mounting point at the passenger side of the lower control arm may deteriorate and cause the steering alignment to change. If the steering alignment changes significantly while the vehicle is in motion this may increase the risk of a vehicle crash.ODI's analysis of complaints it has received from the public (VOQ's) and Mazda complaint data submitted in response to the information request letter for PE18-006 identified a total of 53 non-duplicative reports alleging incidents in which front cross-member corrosion had progressed to the stage of complete or partial separation of the subject steering or suspension components and another 98 reports alleging premature and/or excessive corrosion of the subject components with no separation. Mazda's recall will inspect the subframe and apply structural reinforcements, anti-corrosive wax and an AC drain tube free of charge. In cases of excessive corrosion, the subframe will be replaced free of charge.All 53 complaints alleging complete or partial separations involved vehicles that will be covered under Mazda's recall, resulting in a failure rate of 108.6 reports per 100,000 vehicles (R/100k) in the recalled population. When all complaints are analyzed by region, 150 involve vehicles included in Mazda's recall (307.3 R/100k) and just 1 involved a MY 2009 through 2010 Mazda6 vehicle not included in 18V-631 (2.8 R/100k). The field data indicate that Mazda's recall adequately covers vehicles with a risk of experiencing premature corrosion-related failure of the subject steering and suspension components in the subject vehicles. Based on Mazda's safety recall, this investigation is closed.The following VOQs allege loss or compromised steering control while vehicle was in motion:11115277, 11115790, 11128449, 10706604, 10846298, 10899584, 11019306, 11033821, 11048014, 11074634, 11078734, 11080014, 11083781, 11090944, 11091913, 11098279, 11101718, 11102209, 11102796, 11110606, 11110773, 11112830, 11113461, 11113963, 11114039, 11114567, 11114939, 11115303, 11119368, 11119423, 11121341, 11123997, 11124647, 11128648, 11128774, 11130281, 11132046, 11133295, 11133511, 11138829, 11139187, 11139486The following VOQs allege subframe corrosion detection prior to subframe failure:11141172, 11131161, 11129747, 11129349, 11129185, 11128591, 11128223, 11124644, 11122948, 11120047, 11119752, 11119362, 11118786, 11118242, 11115432, 11114568, 11114477, 11114061, 11105334, 11104096, 11103756, 11103724, 11101659, 11100420, 11099962, 11097874, 11084411, 11081783, 11034064, 11025276, 10956316Some VOQs have been omitted from this list due to duplicate VOQ submission between ODI records and Mazda records.

Latches/locks/linkages:doors:latch

The Office of Defects Investigation (ODI) opened this investigation based on reports that the doors were failing to properly latch on model year (MY) 2009 Mazda6 vehicles.Complainants alleged that the door would fail to latch, or would not properly latch. ODI received a total of 9 complaints alleging this condition primarily on the front side doors, however any of the four side doors could be affected.In response to ODI's Information Request, Mazda provided 56 consumer complaints related to the alleged problem, and 329 warranty claims.On September 23, 2013, Mazda notified ODI that it would conduct a safety recall on model year 2009-2013 Mazda6 vehicles built from February 4, 2008 through August 24, 2012. This period covers the start of production of the MY 2009 Mazda6 through the end of production for the 2013 model year and totals a population of approximately 161,400 vehicles. Mazda determined that the door latch mounting screws may become loose due to lack of torque during manufacturing and/or unevenness of the door shell in the latch mounting area. If all three door latch mounting screws become loose, the door latch mechanism may not engage, potentially resulting in the doors opening while the vehicle is in motion.To remedy the condition, a thread locking adhesive will be applied to the latch screws on all side doors, and the screws will be tightened to the specified torque.This investigation is closed on the basis of Mazda's announcement of safety recall 13V-425.ODI reports cited above can be reviewed at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10406174, 10448036, 10492403, 10503682, 10508051, 10515258, 10521830, 10535228, 10544489.

Latches/locks/linkages

The Office of Defects Investigation (ODI) opened this investigation based on reports that the doors were failing to properly latch on model year (MY) 2009 Mazda6 vehicles.Complainants alleged that the door would fail to latch, or would not properly latch. ODI received a total of 9 complaints alleging this condition primarily on the front side doors, however any of the four side doors could be affected.In response to ODI's Information Request, Mazda provided 56 consumer complaints related to the alleged problem, and 329 warranty claims.On September 23, 2013, Mazda notified ODI that it would conduct a safety recall on model year 2009-2013 Mazda6 vehicles built from February 4, 2008 through August 24, 2012. This period covers the start of production of the MY 2009 Mazda6 through the end of production for the 2013 model year and totals a population of approximately 161,400 vehicles. Mazda determined that the door latch mounting screws may become loose due to lack of torque during manufacturing and/or unevenness of the door shell in the latch mounting area. If all three door latch mounting screws become loose, the door latch mechanism may not engage, potentially resulting in the doors opening while the vehicle is in motion.To remedy the condition, a thread locking adhesive will be applied to the latch screws on all side doors, and the screws will be tightened to the specified torque.This investigation is closed on the basis of Mazda's announcement of safety recall 13V-425.ODI reports cited above can be reviewed at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10406174, 10448036, 10492403, 10503682, 10508051, 10515258, 10521830, 10535228, 10544489.