2004-2011 Mazda RX-8 Passenger Air Bag Inflator Concern – Safety Recall 2618F

June 24, 2019 NHTSA CAMPAIGN NUMBER: 19V488000

Passenger Frontal Air Bag Inflator May Explode

An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.

 

NHTSA Campaign Number: 19V488

Manufacturer Mazda North American Operations

Components AIR BAGS

Potential Number of Units Affected 211

 

Summary

Mazda North American Operations (Mazda) is recalling certain 2010-2011 Mazda RX-8 vehicles that were previously recalled under recall 18V-716 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 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.

 

Remedy

Mazda will notify owners, and dealers will replace the front passenger air bag inflator with an alternate one, free of charge. The recall is expected to begin July 9, 2019. Owners may contact Mazda customer service at 1-800-222-5500, option 4. Mazda’s number for this recall is 2618F.

 

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


June 21, 2019

Attention: All Mazda Dealership General, Service, and Parts Managers
Subject: Migration of Safety Recalls 9416E, 0617A, 2018A, and 2918J to Safety Recall 2618F Takata Passenger Frontal Air Bag Inflator (Permanent Remedy Repair) Mazda RX-8 vehicles only.

MY 2004-2011 RX-8 vehicles were excluded from the initial July 2018 Launch of Recall 2618F due to lack of permanent remedy parts availability.  In preparation for the migration to Recall 2618F, parts for current recalls 9416E, 0617A, 2018A, and 2918J (F1Z1-57-K80) will not be orderable after 5 pm Pacific Time starting June 21, 2019.  The collection process of any remaining dealer inventory of this part will start on June 25, 2019.  All F1Z1-57-K80 parts for recalls 9416E, 0617A, 2018A, and 2918J must be returned by July 5, 2019.

Note: All vehicles currently in Safety Recall 2618F are not impacted in any way. (2003-2008 Mazda6, 2006-2007 Mazdaspeed6, and 2004-2006 MPV)

Parts for Safety Recall RX-8 affected vehicles in 2618F will start once launched on July 9, 2019.

To support this migration, effective July 5, 2019 at 2:00PM Pacific Standard Time, claims for recalls 9416E, 0617A, 2018A, and 2918J, will no longer be accepted in eMDCS.  Please complete and submit any claim for these four recalls as soon as possible prior to July 5, 2019 as there will be no claim acceptance after this date.

For any RX-8 customers that arrive during this transition period and your dealership does not have parts in stock or after July 5, place the customer in an MCVP (Mazda Courtesy Vehicle Program) vehicle or rental vehicle until the launch of Safety Recall 2618F on July 9th. If using a rental vehicle please use the Warranty Preauthorization form if over 2 days of rental is expected.  

Customers with unrepaired vehicles in recalls 9416E, 0617A, 2018A, and 2918J will be notified by first class mail on July 9, 2018.  Letters will be sent to approximately 44,957, customers, and they will be advised parts are currently available.   Summary of Timeline:

DATE(s) WHAT WILL HAPPEN
June 21 (5pm) Parts ordering turned “Off” at 5:00PM Pacific Time
June 25 ~ July 5 Shipmates to collect current remedy parts
July 5  (2pm) Claims no longer accepted in eMDCS for 9416E, 0617A, 2018A, and 2918J at 2:00PM Pacific Time
July 9 Permanent remedy parts are available for order
July 9 Owner letters mailed to unrepaired customers under 2618F. Repairs using permanent remedy parts begins.

 

Important Safety Notice: The National Traffic and Motor Vehicle Safety Act prohibits the delivery of any subject vehicle without performing the necessary repair for defects or failures. Failure to perform applicable recalls before delivery can result in extensive dealer fines and penalties from the Federal Government. Therefore, you must complete this recall for all affected vehicles in your inventory prior to delivery.

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

  1. Owner Letter are available on MGSS (Mazda Global Service Support) website via MXConnect on July 5, 2019.
  2. Parts and Warranty Information are available on MGSS and eMDCS websites via MXConnect on July 5, 2019.
  3. Repair Procedure will be posted to MGSS by the launch of this campaign on July 9, 2019.
  4. For technical assistance, contact the Technical Assistance Hotline at (888) 832-8477, Option 3.
  5. For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
  6. For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626 Option 2.

Please make certain the appropriate personnel in your dealership are aware of these resources and are familiar with the details of this recall before responding to customer inquiries.

 

Sincerely,

Hideo Takashima
Director, Technical Services Division
Mazda North American Operations


MAZDA DEALER EMAIL

June 25, 2019

Attention: All Mazda Dealership General, Service, and Parts Managers
Subject: Migration of Safety Recalls 9416E, 061 7A, 201 8A, and 291 8J to Safety Recall 2618F Takata Passenger Frontal Air Bag Inflator (Permanent Remedy Repair) Mazda RX-8 vehicles only Reminder — Parts Collection and Warranty Claims

MY 2004-201 1 RX-8 vehicles were excluded from the initial July 201 8 Launch of Recall 2618F due to lack of permanent remedy parts availability. In preparation for the migration to Recall 261 8F, parts for current recalls 9416E, 0617A, 2018A, and 2918J (FIZ1-57-K80) ceased ordering at 5:00 pm Pacific Time on June 21 , 2019. The collection process of any remaining dealer inventory of this part started today, June 25, 201 9. All FIZl-57-K80 parts for recalls 9416E, 0617A, 2018A, and 2918J must be returned by July 5, 2019.

Note: All vehicles currently in Safety Recall 2618F are not impacted in any way. (2003-2008 Mazda6, 2006-2007 Mazdaspeed6, and 2004-2006 MPV)

Parts for Safety Recall RX-8 affected vehicles in 2618F will start once launched on July 9, 2019.

As advised June 21 , 2019, effective July 5, 2019 at 2:00PM Pacific Standard Time, claims for recalls 9416E, 0617A, 2018A, and 2918J, will no longer be accepted in eMDCS. Please complete and submit any claim for these four recalls as soon as possible prior to July 5, 2019 as there will be no claim acceptance after this date.

For any RX-8 customers that arrive during this transition period and your dealership does not have parts in stock or after July 5, place the customer in an MCVP (Mazda Courtesy Vehicle Program) vehicle or rental vehicle until the launch of Safety Recall 2618F on July 9th . If using a rental vehicle please use the Warranty Preauthorization form if over 2 days of rental is expected.

Customers with unrepaired vehicles in recalls 9416E, 0617A, 2018A, and 2918J will be notified by first class mail on July 9, 2019. Letters will be sent to approximately 44,957, customers, and they will be advised parts are currently available.

Summary of Timeline:

DATE(s) EVENTS
June 21 (5pm) Parts ordering turned “Off” at 5:00PM Pacific Time
June 25 -July 5 Shipmates to collect current remedy parts
July 5 (2pm) Claims no longer accepted in eMDCS for 941 6E, 0617A, 2018A, and 291 8J at 2:OOPM Pacific Time
July 9 Permanent remedy parts are available for order
July 9 Owner letters mailed to unrepaired customers under 261 8F. Repairs using permanent remedy parts begins.

Sincerely,

Travis Young
Manager, Recalls, Technical Services Division
Mazda North American Operations


REPAIR PROCEDURE
Recall Campaign 2618F

2004-2011 RX-8 Passenger Air Bag Inflator Concern – Safety Recall 2618F

 

A. VEHICLE INSPECTION PROCEDURE

Verify that the vehicle is within the 2004-2005 or 2006-2011 Model/Year range: 

If the vehicle is within the 2004-2005 Model/Year range, proceed to Repair Procedure B Page 2.  

-If the vehicle is within the 2006-2011 Model/Year range, proceed to Repair Procedure C Page 14.  

– Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Label Recall 2618F 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.

 

eMDCS System – Warranty Vehicle Inquiry Results:

If eMDCS displays: Campaign Label is: Action to perform:
RECALL 2618F OPEN Present Email Dealer Recall Help or Contact Warranty Hotline at (877) 727-6626 option 3 to update vehicle history.
Not present Proceed to “B. REPAIR PROCEDURE”.
RECALL 2618F CLOSED Present Return vehicle to inventory or customer.
Not present Proceed to “C. CAMPAIGN LABEL INSTALLATION”.
RECALL 2618F IS NOT PRESENT Does not apply Recall does not apply to this vehicle. Return vehicle to inventory or customer.

 

B. REPAIR PROCEDURE: Air Bag inflator Replacement Procedure

 

RX-8(FE): 2004-2005MY ONLY         (Part Number: F1Z2-57-K80)

Parts Information: The service parts are available in one box.

 

Outline: 

  1. Remove the inflator from Air Bag Module, then replace it with a modified one.
  2. Return the removed inflator with the following manner and caution.

Caution: 

  • Replaced Inflators must be returned. Be sure to keep the carton box which was used to deliver the new inflator. This box is a mandatory for shipping special goods like airbag related parts / inflator.
  • Pack the removed inflator in this box exactly in the same manner as the new inflator was packed.

 

Repair Procedure B:

Warning: 

  • Perform the replacement in a clean environment. Oil, grease, water, etc on components may cause the air bag modules to fail to deploy in the event of an accident, which may cause serious injury. Do not allow oil, grease, water, etc., spill or get in contact with the airbag components. * Inserting a screwdriver, etc., into the connector of an air bag module may damage the connector and cause the air bag module to deploy improperly, which may cause serious injury. Do not insert any foreign objects into the connectors.
  • Do not disassemble the vehicle part other than instructed here.
  • Do not make an attempt to directly supply electric power to the module and the inflator.
  • Keep the module facing of the pad surface upwards anytime, except while performing replacement work.
  • Do not use the module and new inflator if they happen to fall on the ground.
  • Avoid exposing the module and inflator to temperatures exceeding 194 degrees Fahrenheit.

 

Remove the air bag module assembly.

  1. Turn the ignition switch to the LOCK position.
  2. Disconnect the negative battery cable and wait for 1 min or more.
  3. Remove the glove compartment.
    • Pull the stay damper in the direction shown in the figure, and detach the connecting part between the glove compartment and the stay damper.

 

  • Press the stopper in and remove it.
  • Lower the glove compartment.
  • Detach the clips from the dashboard and remove the glove compartment.

 

  1. Remove the Air Bag Module.

Note: The Air Bag Module cover in many vehicles may be sun damaged, however this is not covered under the recall. Be careful when handling so that any crack does not get worse.

  • Remove the bolts
  • Disconnect the connector

 

Replace the Inflator:

  1. Using a flathead screwdriver, pry out the connector stopper plate. Then disconnect the connector.

 

  1. Loosen the four nuts with non-power tools until the upper surface of the nuts is aligned with the top edge of the screw thread of bolts.
  2. If necessary, for easier inflator removal, depress the four nuts to make a gap between the inflator and air bag module.

Note: Do not depress exessively as the module body may be damaged.

 

  1. Remove the nuts(X4), then move the stopper plate from the air bag module. Discard the removed four nuts and stopper plate.

 

  1. Push the inflator end by thumbs then remove it sliding in the direction as shown.

Caution: Return the removed inflator with required information and pack it in the same carton which the replacement part was sent in. 

 

  1. Paste the felt tape to Straight area (Orange area) the retainer. (Paste in two places)

Note: Do not extend outside the Red line (bolt side), in order to prevent tool contact when tightening the nut.

 

  1. Fold it in half and paste it inside the retainer. Make it the same on both sides.

 

  1. Attach the collar A and C to replacement inflator.

(Location of the collar A: The position is the 1st stage side of the  inflator.)

(Location of the collar C: The position is the 2nd stage side of the  inflator.)

 

  1. Insert to align the side of the retainer and guide line (Black line) of replacement inflator.

 

Align guide line (Black line) with retainer edge.

  1. Insert the inflator up to the position where it touches the stopper.

The connector direction is 15 ° from the bottom of the retainer.

 

  1. Set the new stopper plate (A) by gently pushing until it touches with the inflator side (B).

 

  1. Keeping the condition above, tighten the new nuts by fingers first, then to the specified torque by hand tool in the order of (1) – (2) – (3) – (4) shown in the figure. DO NOT USE ANY POWER TOOL AS YOU MAY SHEAR THE STUDS

Tightening Nut Torque: 3.9 ± 0.4 Nm

 

  1. Connect the wire harness connecter to the inflator at 2 locations.

 

  1. Ensure the connectors are fitted properly.

 

Install the Air Bag Module:

  1. Re-connect the connector, then install the Air Bag Module.

(1) Tighten the bolts.

Tightening Torque: 7.9 – 11.7 Nm

 

  1. Install the glove box.
  2. Connect the negative battery cable.
  3. Turn the ignition switch to the ON position.
  4. Verify that the air bag system warning light illuminates for approximately 6 seconds, and goes out.
  • If the air bag system warning light does not operate, refer to the onboard diagnostic system (air bag system) and perform inspection of the system.

 

C. CAMPAIGN LABEL INSTALLATION

  1. Fill out a blue “Campaign Label” (9999-95-065A-06) with:

CAMPAIGN NO:  2618F

DEALER CODE:  Your dealer code DATE:         Today’s Date.

 

  1. Affix it to the hood or bulkhead as shown:

 

  1. Return the vehicle to customer.

 

C. REPAIR PROCEDURE: Air Bag Module Replacement Procedure

 

RX-8(FE): 2006-2011 MY ONLY  (Part Number: FEZ8-57-K70) Parts Information: The service parts are available in one box.

 

Air Bag Module APPS-7

 

 

Outline: 

  1. Remove the air bag module, then replace it with a modified one.

 

 

  1. Return the removed inflator with the following manner and caution.

Caution: 

  • Replaced Inflators must be returned. Be sure to keep the carton box which was used to deliver the new inflator. This box is a mandatory for shipping special goods like airbag related parts / inflator.
  • Pack the removed inflator in this box exactly in the same manner as the new inflator was packed.

 

 

Repair Procedure C:

Warning: 

  • Perform the replacement in a clean environment. Oil, grease, water, etc on components may cause the air bag modules to fail to deploy in the event of an accident, which may cause serious injury. Do not allow oil, grease, water, etc., spill or get in contact with the airbag components.
  • Inserting a screwdriver, etc., into the connector of an air bag module may damage the connector and cause the air bag module to deploy improperly, which may cause serious injury. Do not insert any foreign objects into the connectors.
  • Do not disassemble the vehicle part other than instructed here. * Do not make an attempt to directly supply electric power to the module and the inflator.
  • Keep the module facing of the pad surface upwards anytime, except while performing replacement work.
  • Do not use the module and new inflator if they happen to fall on the ground.
  • Avoid exposing the module and inflator to temperatures exceeding 194 degrees Fahrenheit.

 

Remove the Air Bag Module Assembly.

  1. Turn the ignition switch to the LOCK position.
  2. Disconnect the negative battery cable and wait for 1 min or more.
  3. Remove the glove compartment.
    • Pull the stay damper in the direction shown in the figure, and detach the connecting part between the glove compartment and the stay damper.

 

  • Press the stopper in and remove it.
  • Lower the glove compartment.
  • Detach the clips from the dashboard and remove the glove compartment.

 

  1. Remove the Air Bag Module Assembly.

Note: The Air Bag Module cover in many vehicles may be sun damaged, however this is not covered under the recall. Be careful when handling so that any crack does not get worse.

  • Remove the bolts
  • Disconnect the connector
  • Remove the Air Bag Module Assembly

 

Replace the air bag module:

 

(This photo is without INFLATOR)

 

  1. Remove Plate and Air Bag Module.

 

  1. Remove webbings from Air Bag Module.

 

 

  1. Attach the both webbings to the retainer hooks of new replacement module.
  2. Install the replacement module.
    • Set the webbing below.
    • Set the webbing on the below.
    • Pass the retainer hook through the hole in the LID.

 

  • Attach the plate to the retainer hook.

Fasten the M6 replacement Nuts in 2 locations with hand tools only. (Red circle)

 

Install the Air Bag Module Assembly:

  1. Re-connect the connector, then install the air bag module.

(1) Tighten the bolts.

Tightening Torque: 7.9 – 11.7 Nm

 

  1. Install the glove box.
  2. Connect the negative battery cable.
  3. Turn the ignition switch to the ON position.
  4. Verify that the air bag system warning light illuminates for approximately 6 seconds and goes out.
  • If the air bag system warning light does not operate, refer to the onboard diagnostic system (air bag system) and perform inspection of the system.

 

  1. CAMPAIGN LABEL INSTALLATION
  2. Fill out a blue “Campaign Label” (9999-95-065A-06) with:

CAMPAIGN NO:  2618F

DEALER CODE:  Your dealer code DATE:  Today’s Date.

 

  1. Affix it to the hood or bulkhead as shown:

 

  1. Return the vehicle to customer.

 


2 Affected Products

Vehicle

MAKE MODEL YEAR
MAZDA RX-8 2010-2011

6 Associated Documents

Manufacturer Notices(to Dealers,etc) – Mazda Dealer Email – June 25, 2019

RCMN-19V488-1083.pdf 431.758KB

Download (PDF, 422KB)


Defect Notice 573 Report

RCLRPT-19V488-6897.PDF 214.806KB

Download (PDF, 210KB)


Recall Acknowledgement

RCAK-19V488-6665.pdf 244.752KB

Download (PDF, 239KB)


Manufacturer Notices(to Dealers,etc) – Mazda Dealer Email – June 21, 2019

RCMN-19V488-8889.pdf 66.322KB

Download (PDF, 65KB)


Recall 573 Report – AMENDMENT 1

RCLRPT-19V488-1885.PDF 214.804KB

Download (PDF, 210KB)


Remedy Instructions and TSB

RCRIT-19V488-1375.pdf 1352.749KB

Download (PDF, 1.29MB)


1 Associated Investigation

Air Bag Inflator Rupture
NHTSA ID: EA15001
Dated opened: February 24, 2015

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.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492


Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V488&docType=RCL


 

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