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

June 15, 2018 NHTSA CAMPAIGN NUMBER: 18V403000

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: 18V403

Manufacturer Mazda North American Operations

Components AIR BAGS

Potential Number of Units Affected 237

 

Summary

Mazda North America Operations (Mazda) is recalling certain 2009-2010 Mazda RX-8 vehicles that were previously recalled under

recall 18V-017 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. Note: This recall supersedes recall 18V017.

 

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

 

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June 15th, 2018 

Subject: Warranty Claim Submission for Passenger Air Bag Inflator Replacement – Affecting Safety Recalls 9416E, 0617A, and 2018A transitioning to 2618F.

Attention: Mazda Dealer Principals, Service Managers, and Parts Managers 

As previously advised Mazda is preparing to transition Recalls 9416E, 0617A, and 2018A to a new permanent remedy inflator recall 2618F launching June 29^th, 2018 using new, permanent remedy inflators with new part numbers. The part numbers affected by this action are GLYA57-K80 and F1Z1-57-K80.  

Again, to prepare for the new inflator kits, parts ordering for Recalls 9416E, 0617A, and 2018A closed on Tuesday, June 12^th at 5:00 PM PST, and any outstanding repairs for these recalls were to be completed by Friday, June 15^th.

Beginning Monday, June 18^th, please make it a priority to do the following for the above 3 recalls:

1. Submit Warranty claims for all COMPLETED recall repairs, use the provided templates for each recall.
2. Claims MUST be submitted into eMDCS by June 27, 2018 at 2pm, Pacific Time in order to accurately count completion statistics for NHTSA reporting and owner mailings for Recall 2618F.
3. Contact the Warranty department with ANY questions or problems regarding 9416E, 0617A, and 2018A claim submissions and we will resolve them.
4. If they exist, submit recall claims for any OPEN Repair orders that have a completed recall. NOTE: Remember, you do not need to have all Warranty or Customer Pay work or Rentals completed on a Repair Order completed to submit this warranty claim.

During the weeks of June 18^th to June 29^th Mazda, along with the hazmat specialist, Shipmate, will work with your dealership to collect all your on hand inventory for part numbers GLYA-57-K80 and F1Z1-57-K80.  Please see the Dealer Email from earlier today sent by the Parts Operations Division.

 

Safety Matters. Your Safety is Important to Mazda.

 

Sincerely,

Akira Ikemoto
Director, Technical Services Division
Mazda North American Operations

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August 17, 2018

Attention:	All Mazda Dealership General Managers, Service Managers, and Parts Managers
Subject:	Warranty Claim Process for an Unrepairable Vehicle and/or Unwilling to Participate Vehicle Owner with a Takata Air Bag Inflator Recall

 

For the Takata air bag inflator recall, the Mazda North American Operations Recall Department has developed a process to specifically address vehicles that cannot be repaired for any number of reasons, including but not limited to: damaged or modified vehicles and vehicle owners who refuse to have a Takata recall completed.  If upon inspection it is found that the vehicle cannot receive the Takata recall, then a warranty claim can be entered for administrative costs and to document this situation.

We have developed very specific guidelines and Warranty claim procedures for unrepairable vehicles or unwilling to participate owners with Takata air bag inflators that are outlined below and available on MGSS in documents for each Takata recall.  Please be aware all claims will be reviewed by the Warranty Department after submission.

NOTE:  Please make sure that you DO NOT refuse to repair a B-Series truck just because it has a “Ford” part.   Ford was the manufacturer of all B-Series trucks after 1994 and the air bag and inflator may fit the steering mechanism even if it is not an OEM part.  The part may say “Ford” or have a Ford Part Number, so please contact the Warranty department at MNAO and they will forward your question to the recall team if you have any concerns on an unrepairable vehicle with an Open Takata recall.

If you believe that a vehicle is in your dealer shop with an open Takata air bag recall that cannot be repaired please follow the procedures below:

1. Contact MNAO Warranty Department to explain why you believe that the vehicle cannot be repaired under the Takata recall. Dealers should not unilaterally decide that a recall repair cannot be performed and must discuss the specific vehicle with MNAO so that MNAO and the Dealer together can try to find possible solutions to complete the recall despite the initial obstacles.  After discussing with MNAO, then the Dealer can proceed with the following steps.
2. If the customer simply refuses to have the Takata recall performed, document on the Repair Order:

“The owner has been informed that this vehicle needs to have Takata recall [add applicable recall #] performed and that their refusal to allow the dealer to perform the necessary recall(s) could result in serious injury or death to any driver or passenger in the vehicle; however the owner has still refused to allow the dealer to perform the recall” and have the customer sign and date their acknowledgement.

1. If the customer refuses to sign the Repair Order, document by writing “Customer refuses to sign” with time and date and service manager signature.
2. If a vehicle has been modified or damaged to an extent that the recall cannot be performed (e.g., if the steering wheel has been replaced with a racing steering wheel that has no airbag), provide a detailed explanation to the owner about what will need to be done in order to bring the vehicle into a condition where the recall can be performed.

NOTE:  Be sure to let the customer know why the vehicle needs additional work in order to be able to complete the Takata recall and what specific items are included within the Takata recall.

4. If the customer agrees to the additional work needed on their vehicle, please proceed to repair and close the Takata recall as usual. If they do not agree to the additional work needed to perform the recall repair, please proceed to step 5.
5. Take clear photos of the modifications and/or damage that shows why the vehicle cannot be repaired under the recall.
6. Document on the Repair Order the modifications and/or damage and the necessary steps and estimate for repair.
7. If the customer refuses the additional work needed to perform the recall repair, document on the

Repair Order : “This vehicle was found to have modifications and/or damage to the airbag system that renders the Recall Remedy unrepairable.  The customer has refused to allow the dealer to perform the necessary recall(s) even though the customer was informed that their decision could result in serious injury or death to any driver or passenger in the vehicle” and have the customer sign and date their acknowledgement.

1. If the customer refuses to sign the Repair Order, document by writing “Customer refuses to sign” with time and date and service manager signature.
2. Submit a claim using the following claim detail listed in the attached documentation and required attachments below:
   1. D01- Copy of Repair Order
   2. D40 – At least 1 clear photo showing the damage/modification.
3. If you have any questions, please contact the Warranty department at warrantydept@mazdausa.com email and they will forward your inquiry to the Recall Team for next steps. You will receive a response in 24 hours or less. Please contact Warranty with any questions, PRIOR to submitting for payment.

DEALER TAKATA RECALL UNREPAIRABLE CLAIM
Warranty Information
Warranty Type Code	R
Process Number	J1806A
Symptom Code	99
Damage Code	99
PNMC	5555-18-001A
Quantity	1
Labor Operation	YY798XRX
Labor Hours	0.4 hrs.
Attachment ID: D01	Copy of the Repair Order
Attachment ID: D40	Photos of the Damage/Modification

 

Frequently Asked Questions:

1. Question: My claim is pending for Warranty review, why?

Answer:  All claims will be reviewed by Warranty to ensure dealers are attaching the proper documents to the claim and are documenting the repair order per policy.

 

2. Question: If not repaired, will the unrepairable claim close the recall?

Answer:  No.  The vehicle air bag inflator was not replaced, so the recall will still remain open in case a new owner in the future decides to allow us to complete the recall.

 

3. Question: Can I use this claim for a non-Takata recall with damage/modification?

Answer: Not at this time, but please follow the documentation guidelines as advised above.

 

4. Question: Will the customer continue to get notices regarding their Open recall?

Answer: The customer is continuing to drive a vehicle that needs a safety recall performed, so they will continue to receive notices to try to convince them to change their mind.

 

5. Question: If the customer chooses not to allow us to repair the vehicle and leaves with an Open recall, will the VIN still count on the Missed Opportunities Report?

Answer:  If a claim is submitted within the required time frame (the reporting month), then we will remove the VIN with an unrepairable claim. However, if your claim is not  submitted or is late, the Missed Opportunity Report will not be able to exclude the VIN.

 

6. Question: What if the customer has a deployed or missing passenger and driver air bag, but only wants to repair one of the air bags?  Can I still claim the unrepairable claim?

Answer:  Yes, since there is one air bag the customer declined to repair.  Please document what was and was not repaired on the Repair Order.

 

Protect what is important to you.

 

Sincerely,

Akira Ikemoto
Director, Technical Services Division
Mazda North American Operations

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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.

 

4. 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.

 

2. 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.
3. 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.

 

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

 

5. 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. 

 

6. 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.

 

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

 

8. 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.)

 

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

Align guide line (Black line) with retainer edge.

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

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

 

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

 

12. 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

 

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

 

14. 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

 

2. Install the glove box.
3. Connect the negative battery cable.
4. Turn the ignition switch to the ON position.
5. 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.

 

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

 

3. 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.

  

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 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.

 

4. 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)

 

2. Remove Plate and Air Bag Module.

 

3. Remove webbings from Air Bag Module.

 

4. Attach the both webbings to the retainer hooks of new replacement module.
5. 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

 

2. Install the glove box.
3. Connect the negative battery cable.
4. Turn the ignition switch to the ON position.
5. 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

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

CAMPAIGN NO: 2618F
DEALER CODE:  Your dealer code
DATE:  Today’s Date.

 

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

 

6. Return the vehicle to customer.

 

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2 Affected Products

Vehicle

MAKE	MODEL	YEAR
MAZDA	RX-8	2009-2010

 

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14 Associated Documents

Manufacturer Notices(to Dealers,etc)- June 27, 2018 – Subject: Takata Safety Recall update for 9416E, 0617A, 2018A affecting the Mazda RX-8

RCMN-18V403-5071.pdf 75.4KB

 

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Manufacturer Notices(to Dealers,etc)- August 17, 2018 – Dealer Email

RCMN-18V403-9133.pdf 252.258KB

 

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Recall 573 Report – AMENDMENT 2

RCLRPT-18V403-9393.PDF 215.367KB

 

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Manufacturer Notices(to Dealers,etc)- August 28, 2018 Attention: Mazda General Managers, Parts and Service Managers Subject: DMV Letters to Mazda owners

RCMN-18V403-6272.pdf 90.472KB

 

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Defect Notice 573 Report

RCLRPT-18V403-6123.PDF 217.502KB

 

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Manufacturer Notices(to Dealers,etc)- June 15th, 2018 – Subject: Warranty Claim Submission for Passenger Air Bag Inflator Replacement – Affecting Safety Recalls 9416E, 0617A, and 2018A transitioning to 2618F

RCMN-18V403-4538.pdf 135.509KB

 

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Remedy Instructions and TSB

RCRIT-18V403-6550.pdf 653.013KB

 

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Manufacturer Notices(to Dealers,etc)- Subject: **UPDATE** – Takata Safety Recall Update for Recall 2618F – Mazda6, Mazdaspeed6 and MPV Launch Delayed until July 6, 2018

RCMN-18V403-0232.pdf 79.984KB

 

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Recall 573 Report – AMENDMENT 3

RCLRPT-18V403-2743.PDF 215.739KB

 

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Manufacturer Notices(to Dealers,etc)- Subject: Takata Safety Recall Update for Recall 2618F – Mazda6, Mazdaspeed6 and MPV Launch Delayed until July 6, 2018

RCMN-18V403-1174.pdf 119.274KB

 

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Recall Acknowledgement

RCAK-18V403-3890.pdf 244.773KB

 

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Manufacturer Notices(to Dealers,etc)- Insurance Email and Letters to CALIFORNIA Mazda owners

RCMN-18V403-2545.pdf 161.029KB

 

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Recall 573 Report – AMENDMENT 4

RCLRPT-18V403-6951.PDF 215.674KB

 

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Remedy Instructions and TSB

RCRIT-18V403-1481.pdf 1352.749KB

 

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

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Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=18V403&docType=RCL

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