2004 Mazda RX-8 problems

What is wrong

Mazda North American Operations (Mazda) is recalling certain 2003-2008 Mazda6, 2004-2005 MPV, 2004 RX-8, and 2006-2007 Mazdaspeed6 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.

Risk

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 remedy is 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 2618F. Note: This recall supersedes recalls 13V130, 14V362, 14V773 and 15V869.

Recall number 19V781000 · Recall details

What is wrong

Mazda North America Operations (Mazda) is recalling certain 2003-2008 Mazda6, 2006-2007 Mazdaspeed6 and 2004 MPV vehicles nationwide. Mazda is also recalling 2005-2006 MPV vehicles in Alabama, Arizona, Arkansas, California, Delaware, the District of Columbia, Florida, Georgia, Hawaii, Illinois, Indiana, Kansas, Kentucky, Louisiana, Maryland, Mississippi, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, South Carolina, Tennessee, Texas, Virginia, West Virginia, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands. On July 9, 2019 this recall was expanded to include certain 2004-2011 RX-8 vehicles that were previously recalled under 16V‑354 but have not yet been repaired. 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 passenger frontal air bag, these passenger air bag inflators may explode due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.

Risk

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 remedy is performed. Mazda will notify owners, and dealers will replace the front passenger air bag inflator with an alternate inflator, free of charge. The recall began July 6, 2018. Mailing to the affected RX-8 owners began July 6, 2019. Owners may contact Mazda customer service at 1‑800‑222‑5500, option 4. Mazda's number for this recall is 2618F. Note: With the addition of the RX-8 vehicles, this recall fully supersedes recall 16V354.

Recall number 18V402000 · Recall details

What is wrong

Mazda North American Operations (Mazda) is recalling certain model year 2003-2008 Mazda6, 2004-2008 RX-8, and 2006-2007 Mazdaspeed6 vehicles. The affected vehicles are equipped with a dual-stage driver frontal air bag that may be susceptible to moisture intrusion and other factors, including manufacturing variability that, over time, could cause the inflator to rupture.

Risk

In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with 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 remedy is performed. Mazda will notify owners, and dealers will replace the driver's frontal air bag inflator with an alternate inflator, free of charge. The recall began on September 12, 2017. Owners may contact Mazda customer service at 1‑800‑222‑5500. Mazda's number for this recall is 1417G. Note: This recall supersedes recall 15V‑382.

Recall number 17V474000 · Recall details

What is wrong

Mazda North America Operations (Mazda) is recalling certain model year 2004-2008 RX-8 vehicles. Heat from the engine and the exhaust may cause the main fuel pump pipe to crack.

Risk

If the fuel pump pipe cracks, fuel may leak, increasing the risk of a fire.

Remedy

Mazda will notify owners, and dealers will replace the fuel pump filter kit, free of charge. The recall began on July 31, 2017. Owners may contact Mazda customer service at 1‑800‑222‑5500. Mazda's number for this recall is 1017E.

Recall number 17V354000 · Recall details

What is wrong

Mazda North American Operations (Mazda) is recalling certain 2004 Mazda RX-8 vehicles. The ball joint socket on the front suspension lower control arm may crack and the ball joint may separate from the socket.

Risk

If the ball joint separates, steering control may be lost, increasing the risk of a crash.

Remedy

Mazda will notify owners, and dealers will replace the front lower control arms, free of charge. The recall began on July 31, 2017. Owners may contact Mazda customer service at 1‑800‑222‑5500. Mazda's number for this recall is 1117E.

Recall number 17V355000 · Recall details

What is wrong

Mazda North America Operations (Mazda) is recalling certain model year 2004-2008 RX-8 vehicles manufactured April 10, 2003, to February 18, 2008. The affected vehicles have fuel pump sealing rings that may deteriorate due to exposure to heat from the engine or exhaust pipe.

Risk

The deteriorated seals may leak fuel, which, in the presence of an ignition source, can increase the risk of a fire.

Remedy

Mazda will notify owners, and dealers will replace the fuel pump sealing ring set and add a thermal insulation pad to the fuel tank, free of charge. The recall began July 31, 2017. Owners may contact Mazda customer service at 1‑800‑222‑5500. Mazda's number for this recall is 0516J.

Recall number 16V793000 · Recall details

What is wrong

On certain passenger vehicles, due to improper forging of the lower control arm, cracks may occur in the ball joint socket.

Risk

In severe driving conditions, the ball may separate from the ball joint socket and a loss of steering may occur, which could result in a crash.

Remedy

Dealers will inspect and, if necessary, replace the control arms. The recall began on august 30, 2005. Owners may contact mazda at 1‑800‑222‑5500.

Recall number 05V325000 · Recall details

What is wrong

If certain passenger vehicles are parked and the engine is operated at high RPM's for an excessive length of time, some of the parts around the exhaust system can melt and produce a variety of malfunctions. Problems caused by the excessive heat build-up can range from inoperative oxygen sensor, neutral switch and back up lights, problems with the parking brakes, malfunctions of the gas gauge and/or possible fuel leaks resulting from heat damage to the fuel tank.

Risk

Fuel leakage, in the presence of an ignition source, could result in a fire.

Remedy

Dealers will inspect and replace parts. The recall began on august 30, 2005. Owners may contact mazda at 1‑800‑222‑5500.

Recall number 05V317000 · Recall details

What is wrong

As a result of an ncap test, certain passenger vehicles are being recalled for improperly wired front passenger seat air bags.

Risk

The air bag will not provide adequate protection when the vehicle is involved in a frontal crash.

Remedy

Dealers will install a new wiring harness in the front passenger seat air bag system. The recall began march 5, 2004. Owners should contact mazda at 1‑800‑222‑5500.

Recall number 04V074000 · Recall details

What is wrong

On certain passenger vehicles with manual transmissions, the heat insulator may be cracked causing abnormal noise.

Risk

Continued operation of the vehicle can cause the insulator to come off and could pose a hazard to following vehicles.

Remedy

Dealers will replace the heat insulator. The recall began march 5, 2004. Owners should contact mazda at 1‑800‑222‑5500.

Recall number 04V075000 · Recall details

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

EA21002

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The investigation now includes all manufacturers and vehicles known to be affected at this time.ODI's investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The five ODI reports cited above can be reviewed online at http://www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

EA15001

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

PE14016

On September 23, 2009, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation to investigate allegations of the clutch pedal bracket failures in MY 2004 - 2006 Mazda RX8 vehicles.In response to an information request letter sent by ODI, Mazda stated that the failure mechanism may be related to an improper fastener attachment sequence to the body.The improper sequence may create a distortion of the pedal bracket and create a stress amplitude during pedal usage that may go beyond the wear out limit of the bracket.Mazda stated that the percentages of vehicles experiencing the defect is low at approximately 1% of the vehicle population projected to 10 years in service based on analysis of warranty claim data that best represented the alleged defect.In terms of risk to motor vehicle safety, Mazda stated that the failure is progressive with warning manifested in noise and difficulty in shifting gears prior to complete failure of the bracket.Mazda also stated that when a bracket fracture occurs the clutch pedal may lean towards the brake pedal however gear shifting becomes impossible prior to any contact of the clutch pedal to the brake pedal. ODI is not aware of any crashes associated with a clutch pedal bracket failure in the subject vehicles.ODI's analysis of warranty claim data provided by Mazda yielded failure rates of approximately 3% projected over 10 years in service. ODI's analysis of Vehicle Owner Questionnaire (VOQ) data complaint indicates that approximately 5% of the VOQ complainants allege they were unable to get out of the roadway as a result of a clutch pedal bracket failure.None of these incidents occurred on a highway. Approximately 7% of the complainants alleged a contact condition after a clutch pedal bracket failure of the clutch pedal to the brake pedal. None of these complaints noted difficulty in getting the vehicle stopped.Mazda has informed ODI that it will conducted an Owner Notification of an extended warranty coverage program increasing the clutch pedal assembly warranty to 8 years and limited at 100K miles for model years 2004 through 2009 RX8 vehicles.A safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by the federal safety agency that a safety-related defect does not exist.The agency will continue to monitor this issue and will take further action if warranted by the circumstances.

PE09045