Recall Campaign 2818I – Front Cross Member Corrosion Concern – 2009-2010 Mazda Mazda6

NHTSA Campaign Number: 18V631
Manufacturer Mazda North American Operations
Components SUSPENSION, STRUCTURE
Potential Number of Units Affected 48,814

 

Road Salt Causing Corrosion of Cross Member

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.

 

Summary

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.

 

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 is expected to begin November 12, 2018. Owners may contact Mazda customer service at 1-800-222-5500 Option 4. Mazda’s number for this recall is 2818I.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Mazda has a Recall


2009-2010 Mazda6 – Front Cross Member Corrosion Concern Recall Campaign 2818I


A. INTERIM VEHICLE INSPECTION PROCEDURE UNTIL PARTS ARE AVAILABLE

  1. Subject vehicles

2009 Mazda6 (HP) and 2010 Mazda6 (HZ) vehicles, which were originally sold in, or currently or previously registered in Salt Belt States listed below.

 

23 “Salt Belt” States:
Connecticut Delaware District of Columbia 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

 

Model Subject VIN range Subject production date range
2009-2010MY Mazda6 1YV HP**** 95 M00001 – M52259

1YV HZ**** A5 M00014 – M58879

From February 4, 2008 through October 1, 2010

The asterisk symbol “*” can be any letter or number.

 

  • If the vehicle is within the above ranges, proceed to Step 2.
  • If the vehicle is not within the above ranges, return vehicle to the customer or inventory.

Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Labels Recalls 2818I attached to the vehicle’s hood or bulkhead. Refer to eMDCS System – Warranty Vehicle Inquiry Results table below.

                 NOTE:  Be sure to verify Recall number as the vehicle may have multiple Recall labels.

 

Campaign Label CAMPAIGN LABEL

 

eMDCS System – Warranty Vehicle Inquiry Results:

If eMDCS displays: Campaign Label is: Action to perform:
RECALL 2818I OPEN Present Contact the Warranty Hotline at (877) 727-6626 option 3 to update vehicle history.
Not present Proceed to “B. REPAIR PROCEDURE”.
RECALL 2818I CLOSED Present Return vehicle to inventory or customer.
Not present Proceed to “C. CAMPAIGN LABEL INSTALLATION”.
RECALL 2818I IS NOT PRESENT Does not apply  Recall does not apply to this vehicle. Return vehicle to inventory or customer.

 

B. CROSS MEMBER INSPECTION PROCEDURE 2009-2010 MAZDA6

On certain subject vehicles in salt belt states, it is possible that the front cross member may be corroded due to possible insufficient paint coating.  Corrosion may be more severe on the portion just under the air conditioner drain, causing a perforation.

Continued use of the vehicle with such condition may allow the perforation to progress, and the support of the right lower control arm front bushing to decrease. This may result in a change of the right front wheel alignment.

The vehicle having such conditions may exhibit the concerns as described below.

  • Vehicle stability concerns (steering wheel off center, and pull to right side while driving/braking in a straight line)
  • The Right Front tire may interfere with the mud guard, causing an abnormal noise and vibration.
  • Cross member may fracture due to a heavy impact with a large pothole etc. Under high speed driving with such condition, it is possible that the steering control may become difficult.

Check the condition of the cross member, and determine if it is OK or Not OK based on the inspection criteria.

OK: No perforation due to corrosion exists in the specific areas of the cross member.

NOT OK: Perforation due to corrosion exists in the specific area(s) of cross member

 

If a rust hole exists in the specific area, the cross member may be broken due to a heavy impact with a large pothole

  1. If even one hole exists at the inspection areas Zone No.1 to Zone No.3 the vehicle will require replacement of the cross member.
  1. If a hole exists in an area other than Zone No.1 to Zone No.3, the structural rigidity of the cross member can be maintained through the installation of a reinforcement side member and a new A/C drain hose and the application of an Anti-Rust Cavity wax.
  1. Remove the Aerodynamic under cover No.2 for I4 engine vehicles. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

Note: There is no Aerodynamic under cover No.2 for V6 engine vehicles.

Aerodynamic

 

  1. Remove the right front tire.
  1. Remove visible clips of side cover of right front tire house. Then bend the side cover so that Inspection point Zone No.1: Upper surface of the cross member can be seen

side cover

 

  • Inspection contents

Check for perforation at all three areas by visual inspection: Top Surface, Inside and Side.

If the even one hole exists at these points Zone No.1 to Zone No.3, the vehicle needs replacement of cross member.

Meanwhile, even if there are holes at other places, except holes at Zone No.1 to Zone No. 3 points, the vehicle doesn’t need replacement of the cross member. Instead, the subject vehicle will require the installation of the reinforcement side member and the A/C drain hose and wax application.

 

Top View – Area affected (Right Top Side)

Top View – Area affected (Right Top Side)

 

Zone 1 Inspection – Upper Surface/Top side

Zone 1 Inspection – Upper Surface/Top side

 

If the cross member fails inspection in this Zone, take a clear photo showing the failure. You will need it for later.

 

Zone 2 Inspection – Inside Corner/Flange Weld

Zone 2 Inspection - Inside Corner/Flange Weld

If the cross member fails inspection in this Zone, take a clear photo showing the failure. You will need it for later.

 

Zone 3 Inspection – Outer Area

Zone 3 Inspection - Outer Area

If the cross member fails inspection in this Zone, take a clear photo showing the failure. You will need it for later.

 

Additional Failure Examples of Zones 1 through 3

Additional Failure Examples of Zones 1 through 3

Additional Failure Examples of Zones 1 through 3

Additional Failure Examples of Zones 1 through 3

 

Photos of the bracket installation

Photos of the bracket installation

 

Process for handling failed inspections:

Process for handling failed inspections:

 

To help you effectively perform this inspection portion of the recall, Mazda has developed the following resources:

  1. Inspection Procedures are available on MGSS (Mazda Global Service Support) website via MXConnect.
  2. For technical assistance, contact the Technical Assistance Hotline at (888) 832-8477, Option 3.
  3. For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
  4. For Rental Authorization, Not MCVP, please use the Dealer Recall Help Form on MXConnect. Attach photos of cross member perforation, VIN, Mileage and RO#, and Recall Pre-Authorization form.

 

Warranty Inspection Information 

Inspection of the cross member only
Process Number AJ047A
Symptom Code 99
Damage Code 99
Part Number Main Cause 7777-SP-P54
Quantity 0
Labor Operation Number & Labor Hours Operation No. Labor hours
XXP8YXCX 0.5

TO: All Mazda Dealership General, Service, and Parts Managers
DATE: September 14, 2018
SUBJECT: 2009-2010 Mazda6 – Front Cross Member Corrosion Concern Recall Campaign 2818I

 

On September 14, 2018 Mazda Motor Corporation notified the National Highway Transportation Administration (NHTSA) to conduct a recall for a defect which relates to motor vehicle safety that exists in approximately 48,814 2009-2010 Mazda6 vehicles sold or ever registered in “Salt States”.

 

What is the Problem:

On certain subject vehicles operated in the salt belt states, it is possible that the cross member may be corroded due to suspect insufficient paint coating.  Corrosion may be more severe on the portion just under the air conditioner drain causing a perforation.

Continued use of the vehicle with such condition may allow the perforation to progress, and the support of the right lower control arm front bushing to decrease. This may result in a change of the right front wheel alignment. The driver may experience a heavy pull to the right, and in some cases, it is possible that the steering control may become difficult.

Parts for this recall are not yet available. In the coming weeks Mazda will work with the supplier to expedite repair parts for this concern. The purpose of this recall is to inspect the front cross member and install a side member (for reinforcement), replace the A/C drain hose, and apply rust proofing wax to the cross member. In severe cases the front cross member will be replaced along with the A/C drain hose instead of the side member.

Owners of affected vehicles will be notified of this recall by first class mail no later than November 12, 2018.  Inspection procedure and other information will be posted on MGSS next week when available.  Repair Procedures, Parts and Warranty information and Owner Notification documents will be posted by November.

We  apologize  for  any  inconvenience  this  recall  may  cause  you  and  your  customers.  Your understanding and support in carrying out this campaign is greatly appreciated.

 

Protect What is Important to You.

Sincerely,

 

Akira Ikemoto
Director, Technical Services Division
Mazda North American Operations


TO: All Mazda Dealership General, Service, and Parts Managers
DATE: September 24, 2018
SUBJECT: ***UPDATE*** Interim Inspection Procedure Now Available
2009-2010 Mazda6 – Front Cross Member Corrosion Concern Recall Campaign 2818I

 

An Interim Vehicle Inspection Procedure has been developed for those vehicles that arrive, or are currently at the dealership prior to the launch of the recall.

 

Interim Vehicle Inspection Procedure/Tracking:

Follow the Interim Inspection Procedure posted on MGSS. The vehicle should be inspected for corrosion holes or cracks in at least one place at specific points on the cross member. If the vehicle has been determined to need repair, please follow these vital instructions: Pictures will be required.

  • DO NOT return the vehicle to the customer.
  • Contact Mazda Warranty Department via the new Dealer Recall Help Form on MXConnect > Warranty.
  • Provide photos of cross member perforation, VIN, Mileage and RO#.
  • Offer a MCVP vehicle until parts are available in order to provide the best customer experience.
  • If your dealership cannot provide a MCVP vehicle immediately, you must request rental vehicle authorization from the Warranty Department, and provide the expected date the customer can be transferred into a MCVP Loaner. A new Recall Pre-Authorization request form will be posted in MGSS under this recall for any rental authorization request.
  • DO NOT request rental authorization from your District Field Manager or CEC (Customer Experience Center). The Warranty and Recall Operations teams will be tracking all downed vehicles.
  • Submit an inspection claim through eMDCS

 

NOTE:  New cross members should be available in limited quantities by early December, 2018. Once parts are available an order will be placed and sent for each downed vehicle.

 

We apologize for any inconvenience this recall may cause you and your customers. Your understanding and support in carrying out this campaign is greatly appreciated.

 

Protect What is Important to You.

 

Sincerely,

 

Akira Ikemoto
Director, Technical Services Division
Mazda North American Operations


Remedy Instructions and TSB

https://static.nhtsa.gov/odi/rcl/2018/RCRIT-18V631-7590.pdf

Download (PDF, 871KB)


Miscellaneous Document – 2009-2010 Mazda6 – Front Cross Member Corrosion Concern Recall Campaign 2818I – Parts and Warranty Information on last page

https://static.nhtsa.gov/odi/rcl/2018/RMISC-18V631-7505.pdf

Download (PDF, 1.08MB)


Manufacturer Notice

October 3, 2018

https://static.nhtsa.gov/odi/rcl/2018/RCMN-18V631-0414.pdf

Download (PDF, 58KB)


***UPDATE*** Interim Inspection Procedure Now Available

September 24, 2018

https://static.nhtsa.gov/odi/rcl/2018/RCMN-18V631-1459.pdf

Download (PDF, 41KB)


Manufacturer Notice

September 14, 2018

https://static.nhtsa.gov/odi/rcl/2018/RCMN-18V631-3403.pdf

Download (PDF, 186KB)


Miscellaneous Document – Recall Rental and Additional Damage Pre-Authorization Form – FINAL

https://static.nhtsa.gov/odi/rcl/2018/RMISC-18V631-2863.pdf

Download (PDF, 93KB)


Miscellaneous Document – 2818I Tracking Form – Recall Rental and Additional Damage Pre-Authorization

https://static.nhtsa.gov/odi/rcl/2018/RMISC-18V631-5601.pdf

Download (PDF, 51KB)


Recall Acknowledgement

October 9, 2018

https://static.nhtsa.gov/odi/rcl/2018/RCAK-18V631-6860.pdf

Download (PDF, 246KB)


 

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