2016 Mazda MX-5 Undercover Welding Concern Safety Recall 3619F

June 27, 2019 NHTSA CAMPAIGN NUMBER: 19V496000

Skid Plate and Bracket May Detach

Parts that separate from the vehicle may become a road hazard, increasing the risk of a crash.

 

NHTSA Campaign Number: 19V496

Manufacturer Mazda North American Operations

Components STRUCTURE

Potential Number of Units Affected 2,476

 

Summary

Mazda North American Operations (Mazda) is recalling certain 2016 Miata MX-5 vehicles. The skid plate and metal bracket may detach from underneath the vehicle.

 

Remedy

Mazda will notify owners, and dealers will replace the skid plate, free of charge. The recall began August 2, 2019. Owners may contact Mazda customer service at 1-800-222-5500, option 4. Mazda’s number for this recall is 3619F.

 

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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REPAIR PROCEDURE
Recall Campaign 3619F

2016 MX-5 Undercover welding Concern Safety Recall 3619F

A. VEHICLE INSPECTION PROCEDURE 

1. Verify that the vehicle is within the following ranges:

Model	Subject VIN range	Subject build date range
2016MY MX-5	JM1ND**** G0 100680 – 103315	From May 26,2015 through July  6,2015

 

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.

2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Labels Recalls 3619F 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 3619F OPEN	Present	Contact the Warranty Hotline at (877) 727-6626 option 3 to update vehicle history.
	Not present	Proceed to “B. REPAIR PROCEDURE”.
RECALL 3619F CLOSED	Present	Return vehicle to inventory or customer.
	Not present	Proceed to “C. CAMPAIGN LABEL INSTALLATION”.
RECALL 3619F IS NOT PRESENT	Does not apply	Recall does not apply to this vehicle. Return vehicle to inventory or customer.

 

B. REPAIR PROCEDURE: Front cross member under cover Removal/Installation

ACTION TO BE TAKEN

1. Lift up the vehicle.
2. Remove bolts.

3. Remove the front cross member under cover.
4. Install new under cover in the reverse order of removal.

 

C. CAMPAIGN LABEL INSTALLATION

1. Fill out a blue “Campaign Label”

(9999-95-065A-06) with Campaign No:  “3619F”, your dealer code, today’s date.

 

Affix it to the hood or bulkhead as shown:

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PARTS AND WARRANTY INFORMATION
Recall Campaign 3619F

 

CONDITION OF CONCERN

On certain subject vehicles, the metal bracket on the undercover may separate from the vehicle while driving. In the worst case, the metal bracket may fall off from the vehicle, creating a road hazard for other users, increasing the risk of a crash.

 

OUTLINE OF REPAIR

Replace the undercover with modified one.

Please refer to the Repair Procedure document on MGSS for the details.

 

SUBJECT VEHICLES

Model	Subject VIN range	Subject build date range
2016 MY MX-5 (ND)	JM1ND****G0 100680–103315	From May 26,2015  through July 6, 2015

 

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

 

OWNER NOTIFICATION

Mazda will notify U.S. owners by first class mail beginning by August 6, 2019.

 

PARTS INFORMATION 

Description	Quantity	Remarks	Part Number
COVER UNDER	1	N/A	N247-34-H80-B
BOLT	1.0-9.0	Claim if missing bolt(s) at repair.	9YA0-20-876
Campaign Label	1=50 labels	Obtain in Mazda e-Store (no charge)	9999-95-065A-06

 

 

WARRANTY CLAIM PROCESSING INFORMATION

	Undercover replacement	Scrap
Process Number	AK037A
Symptom Code	99
Damage Code	99
Causal Part No.	N247-34-H80-B	Scrap Immediately
Quantity	1
Labor Operation	XXR87XRX
Related parts number & Qty	9YA0-20-876 & 1.0 – 9.0
Labor Hours	0.3 hrs.	Type R3619F in the eMDCS Claim Template section

 

RENTAL CAR INFORMATION 

Mazda recommends the usage of the MCVP loaner vehicle when available. If all MCVP loaner vehicles are in use and unavailable, and the customer needs a rental car, then use your local rental facility and offer a rental car. Be sure that every effort is made to repair the car within one business day or less in order to allow the next customer the same experience.

 

Rental Car Warranty Claim Information 

	MCVP Vehicle Preferred	Rental Agency Vehicle
Warranty Type Code	N/A MCVP does not require claim submission	A
Symptom Code		99
Damage Code		99
Part Number Main		5555-36-19FR
Part Quantity		0
Labor Operation Code		MM024XRX
Labor Hours		0
Sublet – Rental Car
Sublet Invoice Number		Number from Rental Invoice or Dealer Purchase Order
Sublet Type Code		Enter “Z9” (other)
Sublet Amount		Up to $30.00 per day for the number of days customer
Sublet Text		Number of days rental car was

 

Rental expenses exceeding the two-day limit will require prior Warranty Department Authorization, as outlined in the Mazda Rental Car Reimbursement Program policy.

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IMPORTANT SAFETY RECALL

2016 MX-5 – Undercover Welding Concern Safety Recall 3619F
NHTSA Campaign Number 19V-496

 

August 2019

This notice applies to your vehicle: VIN _______________

 

Dear Mazda Owner:

This notice is sent to you in accordance with the National Traffic and

Motor Vehicle Safety Act.

Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists in certain 2016 model year MX-5 vehicles produced from May 26, 2015 through July 6, 2015.

 

If you received this notice, your vehicle is included in this Recall.

 

What is the problem?

On certain subject vehicles, the metal bracket on the undercover skid plate may separate from the vehicle while driving, due to insufficient welding strength between the undercover and metal bracket. This could result in the metal bracket falling off the vehicle, creating a road hazard for other users, and increasing the risk of a crash.  

1. Under cover
2. Bracket

 

 

What will Mazda do?

Protect What Is Important To You

Your Mazda dealer will replace the undercover. The repair will be performed at no cost to you.

 

How long will it take?

It will take approximately half an hour to complete the repair; however, your Mazda dealer may need your vehicle for a longer period of time.

Mazda will provide alternate transportation, if needed, when your vehicle is at an authorized Mazda dealership for a recall repair. Schedule an appointment with an authorized Mazda dealer so they can discuss and accommodate your needs.

 

What should you do?

Mazda is concerned about your safety, and we encourage you to contact any authorized Mazda dealer to schedule an appointment to have your Mazda vehicle repaired as soon as possible. You do not need to bring this notice to the dealer, but it may assist in the check-in process.

What if you already paid for repair related to the concerns outlined in this recall campaign?

If you have already paid for repair or parts replacement due to conditions similar to this recall campaign prior to receiving this notice, you may be eligible for reimbursement of reasonable repair expenses based on Mazda’s repair standards. Please complete the enclosed “Reimbursement Application Form”, include the necessary documentation, and mail it to us in the pre-addressed envelope provided, allowing 6-8 weeks for processing.

Where is the closest Mazda dealer?

To locate your nearest Mazda dealer, visit our website www.MazdaRecallInfo.com, or call our Customer Experience Center at (800) 222-5500, option #4.

 

Moved or no longer own this vehicle?

If you have moved or no longer own your Mazda vehicle, please complete and mail the enclosed postage-paid Information Change Card (no envelope required) as soon as possible. This enables us to update our records and notify the current owner.

Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Still have questions?

If you have any questions regarding this campaign, please contact our Customer Experience Center toll free at (800) 222-5500, option #6.

If Mazda or its dealers do not repair the defect free of charge and within a reasonable amount of time, you may notify the Administrator of the National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1888-327- 4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov.

As a reminder, you can always go to www.MazdaRecallInfo.com and enter your VIN to view recalls and service campaigns that apply to your vehicle as well as register to receive future recall alerts.

Your safety is our first priority at Mazda. We actively work to improve our products and search for solutions to improve your ownership experience. We apologize for any inconvenience this recall may have caused you.

Sincerely,

Mazda North American Operations

 

Para información en español, visite www.MazdaSeguridad.com o llame a nuestro Centro de Experiencia para el Consumidor al (800) 222-5500, opción #8 para hablar con un representante en español.

 

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Chronology of Defect
Possible Undercover fall off on MY 2016 MX-5

 

December 24, 2015: Mazda received a first field report “Noise came from under cover” from U.S. market which only reported a noise concern, and tried to collect the subject parts.

January 26, 2016: Mazda received the subject parts from the U.S. It was found that several of the twelve total welding points had separated.

March 22, 2016: As the result of detailed investigation of the returned parts, rapid degradation at the welding points was confirmed, but the welding performance was believed to meet design specifications. Mazda adopted measuring the size of welds as a method to ensure the welding specification is being met.

May 17, 2016: Mazda began to considerate the welding specification to control the performance of the weld properly.

September 12, 2016: The root cause was not identified. However, no similar concerns were received from the field, so Mazda believed this case was caused by external factors. Mazda decided to monitor the occurrence of similar issues in the field.

December 1, 2016: Mazda changed the welding specification control method from measuring the weld size to the actual strength measurement at the welding points as a quality assurance measure.

February 2, 2018: Mazda received a second field report regarding noise from the undercover.

March 26, 2018: Mazda received a third field report from Europe that the undercover bracket loosened from the undercover during driving. From receipt of first field report to August, 2018, Mazda received a total of 10 field reports from Europe regarding the undercover welding issue.

June 21, 2018: It was found that all cases of welding separation occurred on vehicles produced in June 2015. Mazda confirmed that the weld separation issue related to a prolonged welding tool replacement cycle in production. The parts supplier had revised the tool replacement cycle in July 2015. There has been no separation of parts manufactured before or after this time frame.

September 13, 2018: Mazda collected vehicle undercover parts from field vehicles in use. As a result of investigating returned parts, Mazda found that with increasing number of parts welded by a single welding tool, the welding strength became weaker.

October 15, 2018: Mazda began to evaluate the possibility of any safety risk.

March 11, 2019: Per the safety risk evaluation, if the undercover bracket completely separates from the vehicle, especially when driving at high speed, following vehicles may run over the bracket, leading to safety risk of contacting other vehicles.

June 10, 2019: Mazda identified the potentially affected subject vehicle production range.

June 24, 2019: Mazda held a Quality Audit Committee to review all available information to date and determined to conduct a proactive field action on certain MY2016 MX-5 vehicles..

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MAZDA DEALER EMAIL

August 1, 201 9

Attention: Mazda General, Parts and Service Managers

Subject: Launch of Safety Recall 3619F – 2016 MX-5 — Undercover Welding Concern

Mazda Motor Corporation has decided to conduct a Safety Recall Campaign on certain 201 6 MX5 vehicles, affecting 2,476 U.S. and U.S. Territory vehicles.

Affected Vehicles:

Model	Subject VIN range	Subject production date range
2016MY MX-5	JMI ND GO 100680- 103315	From May 26, 201 5 through July 6, 2015

 

Concern Outline:

On certain subject vehicles, the metal bracket on the undercover skid plate may separate from the vehicle while driving, due to insufficient welding strength between the undercover and metal bracket. This could result in the metal bracket falling off the vehicle, creating a road hazard for other users, and increasing the risk of a crash.

1. Under cover
2. Bracket

 

Owner Notification:

Mazda will notify 2,640 owners of affected vehicles by first class mail on August 2, 2019. Owners will be asked to bring their vehicle to the nearest Mazda dealership for repairs.

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. Parts and Warranty information, Repair procedures and the Owner Letter are posted on MGSS (Mazda Global Service Support) websites via MXConnect.
2. Parts and Warranty information is also available in eMDCS.
3. For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
4. 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.

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

Mazda North American Operations

Sincerely,

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

MAZDA NORTH AMERICAN OPERATIONS

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MAZDA DEALER EMAIL

June 28, 2019

Attention: Mazda General, Parts and Service Managers

Subject: 2016 Mazda MX-5 Undercover Welding Concern Recall Campaign 3619F

Mazda Motor Corporation has decided to conduct a Safety Recall Campaign on certain 201 6 Mazda MX-5 vehicles, produced from May 26, 201 5 through July 6, 2015 affecting 2,476 US and U.S. Territory vehicles.

 

Action Required:

As a reminder all vehicles under this recall will show as “Not Launched” status in eMDCS and can be repaired once parts and warranty information is available on MGSS by July 6^th After repairs, please hold the recall claim until the parts and warranty information is available on MGSS, approximately July 6^th .

 

Concern Outline:

On certain subject vehicles, the metal bracket on the undercover may separate from the vehicle while driving. In the worst case, the metal bracket may fall off from the vehicle, creating a road hazard for other users, increasing the risk of a crash.

Causal factor: The welding strength between the undercover and metal bracket is insufficient.

Affected Vehicles:

Model	Subject VIN range	Subject production date range
2016 MX-5	JM1ND**** G0 100680 – 103315	From May 26, 2015 through July 6, 2015

 

Owner Notification:

Mazda will notify owners of affected vehicles by first class mail no later than August 23, 2019. Owners will be asked to bring their vehicle to the nearest Mazda dealership for repairs.

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:

Parts and Warranty information, Repair procedures will post on MGSS (Mazda Global Service Support) websites via MXConnect as soon as available, approximately July 6, 201 9.

2. For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
3. For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626 Option 2.
4. Vehicles will display in eMDCS as “Not Launched” on June 29, 2019. Once Parts and Repair procedures are posted, repairs can be completed any used in-stock units as well as customer vehicles that exhibit the condition or that cannot wait.

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.

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

Mazda North American Operations

Sincerely,

Hideo Takashima
Director, Technical Services Division
Mazda North American Operations

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1 Affected Product

Vehicle

MAZDA

MX-5

2016

 

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11 Associated Documents

Manufacturer Notices(to Dealers,etc)- Launch of Safety Recall 3619F-2016 MX-5 – Undercover Welding Concern.

RCMN-19V496-3090.pdf 436.769KB

 

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Recall Quarterly Report #1, 2019-3

RCLQRT-19V496-0531.PDF 211.143KB

 

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Recall Quarterly Report #2, 2019-4

RCLQRT-19V496-8163.PDF 211.242KB

 

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Chronology

RMISC-19V496-4505.pdf 14.857KB

 

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Miscellaneous Document – PARTS AND WARRANTY INFORMATION Recall Campaign 3619F

RMISC-19V496-4319.pdf 211.928KB

 

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Defect Notice 573 Report

RCLRPT-19V496-1250.PDF 212.951KB

 

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Remedy Instructions and TSB

RCRIT-19V496-9971.pdf 340.509KB

 

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Recall Acknowledgement

RCAK-19V496-7757.pdf 244.626KB

 

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Manufacturer Notices(to Dealers,etc) – Mazda Dealer Email – June 28, 2019

RCMN-19V496-5298.pdf 374.806KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-19V496-2440.pdf 208.186KB

 

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Recall Quarterly Report #3, 2020-1

RCLQRT-19V496-7265.PDF 211.33KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V496&docType=RCL

 

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