2024 Mazda CX-90 Plug-In Hybrid: engine stalls while driving

Filed Dec 11, 2025 · Electrical, Engine · TX

I am reporting serious safety concerns with my Mazda CX-90 PHEV (leased, manufactured September 2023). These issues create unacceptable risk to occupants and other road users. Multiple Severe Recalls: My vehicle has had at least four major recalls: • 6323J – Engine & Motor Shutdown: Complete loss of propulsion without warning. • 7024J – ECU Software Failures: Loss of drive power and restart failures. • 24V817000 – EV Mode Power Loss: Sudden propulsion loss in EV mode. • 6724E – Sudden Braking: Automatic braking without cause. These defects could lead to crashes or fatalities. Hybrid System Malfunctions: Two recent “Hybrid System Malfunction” warnings required dealer visits. These failures could cause the car to shut off while driving—even at highway speeds. • First incident: Battery-related issue. • Second incident: Triggered by a loud noise during startup, impacting the AVAS system. A loud noise should never disable a family vehicle, indicating a design flaw. Charging Safety Issues: Charging via a standard outlet caused flickering lights and breaker buzzing in my house. A licensed electrician diagnosed harmonic distortion from the onboard charger. I spent $7,500 on electrical upgrades (dedicated EV line and panel upgrade) to charge safely. Manufacturer Response: I have had an open case with Mazda corporate for nearly two weeks. They refuse to acknowledge overall vehicle safety or provide written documentation confirming safety. Request: I urge the federal safety agency to investigate whether these defects represent a systemic safety issue in Mazda CX-90 PHEV models and take appropriate regulatory action

Filed Nov 5, 2025 · Electrical · MA

My 2024 Mazda CX-90 continues to have a malfunctioning fuel gauge despite multiple dealer visits and the recall repair (Recall 25V568). The dealer confirmed the issue was fixed, but it is not. The digital fuel gauge does not update in real time. It remains stuck for long distances and only partially recalibrates after restarting the car. For example, on November 5, 2025, I drove more than 60 miles, but the gauge dropped by only about 10 miles. After turning the ignition off and on, the gauge adjusted slightly but still did not reflect the true fuel level. Photos from that day are attached. I have serious safety concerns. The recall notice states: “If the vehicle incorrectly indicates an inaccurate fuel level, there is a chance of unexpectedly running out of fuel while driving. This would result in an engine stall and vehicle being unable to restart, increasing the risk of a crash.” This issue persists even after the recall service was completed, suggesting that the current fix may not fully resolve the defect. This has been an ongoing issue. I visited the dealership again on Nov 5th, 2025.

Filed Apr 18, 2024 · Electrical, Transmission · WA · crash

Driving up snowy pass on I-90 approaching the top of Snoqualmie Pass. Vehicle stalled and warning lights flashed critical warning and loss of power. The vehicle stopped in the middle of the highway and would not start or go into drive. After a few minutes, because of speeding and adverse conditions, another driver collided with my vehicle from behind. Another following vehicle lost control and ran off the road. Nobody was injured. Mazda has not provided any information to what happened with the vehicle. We added about 12k miles in the 5 months of driving it, so we had lots of testing with it, and never ran into this serious of an issue with this or any other vehicle.

Filed Feb 24, 2024 · Acceleration, Electrical · CA

On [XXX], I was driving on [XXX] near Pasadena at normal speed of traffic when suddenly an error message “Hybrid System Malfunction” appeared on the dash board along with check engine light, and the car began to stall slowing down to nearly full stop almost immediately. When I pressed gas pedal, it would not accelerate. Because I was in the far right lane, I had just about enough time to pull over onto the shoulder before the car stopped completely. The car was in EV mode (using all electric power) when this incident occurred with 20 miles of electric range still left. I was lucky that no cars were right behind me as the traffic was moving about 60 mph or my car could have been rear-ended when it came to such an abrupt stop. I put the car in park and turned off the engine, then turned it back on after a couple of minutes. The dashboard was flashing “Hybrid System Malfunction” and “check engine” light was on but I was able to drive it because it had switched to gas power mode. I immediately drove the car to New Century Mazda in Alhambra where I purchased it on [XXX]. The Mazda app on my phone captured two Vehicle Issues Detected at the same time: Hybrid System Malfunction: There is a possibility of restricted power output” and “i-ACTIVSENSE malfunction.” The Hybrid System Malfunction was the most serious and frightening of a series of malfunctions that my car experienced since it was purchased two months ago. On [XXX] (4 days after purchase) the car displayed “Approaching Vehicle Audible System (AVIS) Malfunction,” on [XXX], a “Brake!”light came on when we started the car after it had been parked, which disabled the steering wheel and the gear shift preventing us from driving (problem resolved by turning the car on and off several times). On [XXX], another vehicle issue was detected: “Air bag system and seatbelt pre-tensioner system malfunction.” Car was fully inspected by Mazda dealer in mid-January. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Feb 5, 2024 · Acceleration, Electrical · CO

While driving CX90 PHEV vehicle, a "HAZARD" error displayed on the dashboard and the vehicle stopped driving/accelerating completely. Displayed error reported a Hybrid System Malfunction and instructed driver to switch from hybrid to normal setting. Vehicle would not accelerate despite switch to normal setting and power remaining. Driver powered off vehicle and error remained on display. Driver again powered off vehicle after short wait and error was no longer displayed. Vehicle could then be driven in normal setting. Dealership and manufacturer have been notified with a request for immediate assistance. Vehicle is new and has only been driven for approx. 6 months. No advance warning signs appeared. Internet search reflects a Mazda owners' forum page [XXX] suggests that error has been known for several months with no resolution or recall. A vehicle that shuts down while driving in traffic is a hazard to us all. Responses are requested from both Mazda and the federal safety agency. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)