4821C – Driver’s Air Bag Inflator May Explode – 2007-2009 Mazda B-Series Pickup Trucks

March 10, 2021 NHTSA CAMPAIGN NUMBER: 21V162000

Driver’s 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: 21V162

Manufacturer Mazda North American Operations

Components AIR BAGS

Potential Number of Units Affected 5,844

 

Summary

Mazda North American Operations (Mazda) is recalling certain 2007-2009 B-Series pickup trucks. The driver’s side air bag inflator may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.

 

Remedy

Mazda will notify owners, and dealers will replace the driver-side air bag inflator with an alternate one, free of charge. Owners were notified of the safety risk with an interim letter mailed April 26, 2021. A second letter was sent December 2021. Owners may contact Mazda customer service at 1-800-222-5500 option 4. Mazda’s number for this recall is 4821C.

 

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

 


REPAIR PROCEDURE

1. Remove the driver airbag from the vehicle. Please refer to MGSS online (DRIVER AIR BAG MODULE REMOVAL / INSTALLATION).

2. Set the airbag face down onto a surface that will not scratch or damage the airbag face.

WARNING: Do not allow any debris on or around airbag once the inflator is removed.

1. Remove and discard the 4 airbag inflator retaining nuts from the driver side airbag. See Figure 1.

Do not use any sort of Power Tool!

 

2. NOTE: In order to verify the correct airbag inflator is installed, mark the old airbag inflator with a felt tip marker prior to removal.

– Remove the airbag inflator and set aside for return shipping. See Figure 1

3. NOTE: The new airbag inflator must be installed in the same orientation as the original part

Install the new inflator into the driver airbag. Verify the alignment tab on the airbag housing is aligned with the cut-out on the inflator. See Figure 1

4. Install 4 new airbag inflator nuts onto the driver airbag. See Figure 1. Do not use any sort of power-tool to install these nuts under any circumstance.

• Tighten to 57 in-lb (6.5 Nm). This less than 5 ft-lbs!

5. Re-install the driver airbag

a. Install the driver air bag module. Refer to MGSS online (DRIVER AIR BAG MODULE REMOVAL / INSTALLATION).

b. Reconnect the negative battery cable.

c. Turn the ignition switch to the ON position.

d. Verify that the air bag system warning light illuminates for approx. 6 sec., then goes out.

e. NOTE: If the air bag system warning light does not operate in the manner described above, there is a malfunction in the system. Inspect the system following the on-board diagnostic system procedure according to MGSS.

f. Re-enter the customer’s preset radio stations

 

NOTE: Confirm that the Airbag Readiness light still indicates no SRS faults are present

6. Package the replaced inflator in the new part box and provide to the parts department for part returns. Proceed to the Knee Bolster Bracket Replacement Procedure.

 

Knee Bolster Bracket Replacement Procedure

1. Remove the two hood release handle retainers and position the handle and cable aside. See Figure 3

 

2. Remove the two parking brake handle retainers and position aside. See Figure 4

 

3. Remove the two lower steering column opening trim panel retainers. See Figure 5

 

4. Remove the steering column opening trim panel by pulling the panel toward the rear of the vehicle to release the upper panel clips. See Figure 6

 

5. Remove the five retainers and the steering column opening knee bolster. See Figure 7.

9.1 Tighten to 62 in-lb (7 Nm).

 

6. Using a small hand saw, cut the lower instrument panel substrate in the two areas indicated in Figure 8

CAUTION: Take care not to cut the instrument panel metal frame behind the substrate.

 

7. Remove the lower knee bolster bracket retainer. See Figure 9

 

8. Remove the section of the lower instrument panel, that was cut out previously, and set aside to be used later in this procedure. See Figure 10

 

9. Loosen, but do not remove, the upper knee bolster bracket retainer, then fully remove the center knee bolster bracket retainer. See Figure 11

 

10. Remove and discard the LH instrument panel knee bolster bracket by sliding the lower portion of the bracket off of the alignment pin, then lift the bracket off of the upper bracket retainer. See Figure 12

 

11. Install the new LH instrument panel knee bolster bracket by reversing the removal procedure.

• Tighten the upper and center retainers to 28 in-lb (3.2 Nm).

12. Using a strip of flocked tape from the JVCC FLOCK-1 Flocking Tape or Hush Mat Quiet Tape #30300, measure and cut a 0.75 inch (19mm) x 1.75 inch (44mm) piece of flocked tape. Using the adhesive backing, adhere the piece of flocked tape onto the metal frame half way between the inboard substrate cut, as shown in Figure 13.

 

13. Reinstall the piece of instrument panel substrate that was previously cut out and install the retainer. See Figure 14.

• Tighten to 28 in-lb (3.2 Nm)

 

14. Using clear automotive repair tape, 3M™ Clear Repair Tape (03439), cut a strip 12 inches (304mm) in length. wrap the tape around the inboard cut on the substrate and the instrument panel frame as shown in Figure 15

 

15. Reinstall the items removed from steps 1-5 of the Knee Bolster Bracket procedure above.

 


Chronology of Defect

 

PSDI-5D Driver Frontal Air Bag Inflator May Explode on MY 2007 through MY2009 B-Series

 

July 10, 2017 – Takata submitted Defect Information Report 17E-034 on all PSDI-5D driver side air bag inflators that use “2004” generate with calcium sulfate as a desiccant.

 

August 23, 2017 – Mazda files an inconsequential petition for relief from notification and remedy requirements under the Motor Vehicle Safety Act for the subject air bag inflators (NHTSA ID: 17V466) (DOCKET NO. NHTSA-2017-0092).  As MY2007-2009 B-Series and MY2007-2011 Ford Ranger are designed and manufactured on identical platforms and use identical air bag inflators, Mazda is solely dependent on Ford for engineering investigations, service information, and parts procurements.  Therefore, Ranger data is representative of B-Series.

 

August 2017 to January 2021 – Ford informed Mazda of status regarding collection of field parts and ongoing evaluations by Takata and other independent experts, as it related to Ford’s Ranger and Mazda’s B-Series.

 

January 19, 2021 – NHTSA notified Mazda that the petition was denied.  NHTSA required a proposed schedule for notification of vehicle owners and the launch of a remedy to fulfill those obligations.

 

March 5, 2021 – In fulfillment of the petition requirement for owner notification and remedy, Mazda’s Quality Audit Committee decided to conduct a recall covering the subject vehicles to replace original parts with non-ammonium nitrate-based inflators.  Unlike previous Takata air bags under recall, Mazda filed a petition for relief from notification and remedy requirements because these Takata driver side air bags contain a moisture-absorbing desiccant and perform differently.  However, Mazda respects NHTSA’s decision and is submitting this defect information report pursuant to the plan discussed with the Agency in February 2021.

 

March 19, 2021 – Amended defect information report to revise recall population to 5,847 units from original population of 5,844 units.  Mazda records indicated three vehicles were originally distributed to Mexico, however, they are now confirmed to be in Puerto Rico.

 


 

 


3 Affected Products

Vehicle

MAKE MODEL YEAR
MAZDA B-SERIES TRUCK 2007-2009

 


8 Associated Documents

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

RCMN-21V162-7799.pdf 493.426KB

RCMN-21V162-7799

 


Chronology

RMISC-21V162-2783.pdf 14.827KB

RMISC-21V162-2783

 


Manufacturer Notices(to Dealers,etc)- 4/23/21

RCMN-21V162-3203.pdf 489.854KB

RCMN-21V162-3203

 


Recall 573 Report – Amendment 1

RCLRPT-21V162-4616.PDF 214.584KB

RCLRPT-21V162-4616

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V162-8366.pdf 617.865KB

RIONL-21V162-8366

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V162-5206.pdf 506.582KB

RIONL-21V162-5206

 


Defect Notice 573 Report

RCLRPT-21V162-2931.PDF 215.522KB

RCLRPT-21V162-2931

 


Recall Acknowledgement

RCAK-21V162-8151.pdf 189.637KB

RCAK-21V162-8151

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V162&docType=RCL

 


 

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