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 is expected to begin August 26, 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


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 6th After repairs, please hold the recall claim until the parts and warranty information is available on MGSS, approximately July 6th .

 

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.

  1. For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
  2. For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626 Option 2.
  3. 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


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.
  1. 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.

CAMPAIGN LABEL CAMPAIGN LABEL

 

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.

under cover

  1. Remove the front cross member under cover.
  2. 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.

CAMPAIGN LABEL

 

Affix it to the hood or bulkhead as shown:

CAMPAIGN LABEL


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.


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..


1 Affected Product

Vehicle

MAKE MODEL YEAR
MAZDA MX-5 2016

6 Associated Documents

Chronology

RMISC-19V496-4505.pdf 14.857KB

Download (PDF, 15KB)


Miscellaneous Document – PARTS AND WARRANTY INFORMATION Recall Campaign 3619F

RMISC-19V496-4319.pdf 211.928KB

Download (PDF, 207KB)


Defect Notice 573 Report

RCLRPT-19V496-1250.PDF 212.951KB

Download (PDF, 208KB)


Remedy Instructions and TSB

RCRIT-19V496-9971.pdf 340.509KB

Download (PDF, 333KB)


Recall Acknowledgement

RCAK-19V496-7757.pdf 244.626KB

Download (PDF, 239KB)


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

RCMN-19V496-5298.pdf 374.806KB

Download (PDF, 366KB)


Recalls Documents

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


 

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Last update on 2019-08-09 / Affiliate links / Images from Amazon Product Advertising API

Last update on 2019-08-09 / Affiliate links / Images from Amazon Product Advertising API

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