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January 18, 2024 NHTSA CAMPAIGN NUMBER: 24V022000
Loss of power steering assist while driving increases the risk of a crash.
NHTSA Campaign Number: 24V022
Manufacturer Mazda North American Operations
Components STEERING
Potential Number of Units Affected 43,752
Summary
Mazda North America Operations (Mazda) is recalling certain 2024 CX-90 vehicles. An assembly issue with the worm gear in the steering system may result in a sudden loss of power steering assist.
Remedy
Dealers will replace the spring engaging the worm gear and reapply grease to the gear teeth, free of charge. Owner notification letters are expected to be mailed March 18, 2024. Owners may contact Mazda customer service at 1-800-222-5500 Option 6. Mazda’s number for this recall is 6524A.
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.nhtsa.gov.
Check if your Mazda has a Recall
Announcement of Safety Recall 6524A-2024MY CX-90-Sudden Increase in Steering Effort
Mazda Motor Corporation has decided to conduct a Safety Recall on certain 2024MY CX-90 vehicles. Please see the description, model, year, and VIN range below for the vehicles in this campaign. There are 43,695 vehicles affected with this concern in the US.
Concern Outline: While driving, the customer may feel a sudden increase of effort when steering the vehicle. Sudden and unexpected change of steering effort while driving may increase the risk of a crash. A worm gear is incorporated in the steering gear assembly, which transmits the power assist generated by the power steering motor. The worm gear friction force may be excessive which results in increased force required to turn the steering wheel.
Suspension of Delivery – Mazda Dealer Action Requested:
Currently, there are approximately 10,954 CX-90 vehicles in dealer inventory or in transit to dealers. All Mazda dealers must quarantine any affected new, used, or Certified Preowned Owned (CPO) in-stock vehicle until the repair is completed. The affected dealer inventory list is available on Mazda Global Service Support (MGSS) and was provided to your District Service Manager. The current inventory list will be updated weekly or bi-weekly on MGSS as needed.
Repair Outline: Dealers will reapply grease to the gear teeth and will replace a spring with an improved part that reduces the spring force to the worm gear in the steering gear assembly. This repair was validated at MNAO and there is ample time provided for this recall to complete the repair and take the required photos. Technicians will be required to take 4 clear photographs of specific steps in the repair and those photographs must be attached to the claim for Recall and Warranty claim review prior to acceptance.
REPAIR PROCEDURE
SAFETY RECALL 6524A
Safety Recall – 2024 CX-90 – Steering Gear Safety Recall
VEHICLE INSPECTION PROCEDURE-AND PREPERATION FOR REPAIR
Chronology of Defect on January 18, 2024
Sudden increase in steering effort on MY2024 CX-90
Mazda #6524A
November 24, 2022: Mazda received the first field report, from Japan.
December 12, 2022: Mazda received its second field report, from Sweden. Mazda began to investigate this condition.
March 1~29, 2023: Mazda identified the root cause. It was due to pushed out grease from the gear teeth.
April 6, 2023: Mazda implemented a countermeasure for production vehicles, which modified the teeth shape of the worm wheel to allow for proper application of grease to the gear.
April 30, 2023: Service information was issued in Japan and Europe, where several failures occurred to ensure dealerships were informed of the remedy.
September 27, 2023: The same failure occurred on improved parts, which had the updated worm wheel gear teeth shape. Improvement parts were found to be inadequate.
October 13, 2023: Mazda examined the failure mechanism using the previously improved part and considered further improvement to correct this condition.
October 27, 2023 ~ Nov 8, 2023: Mazda received three field reports from the U.S.
December 11, 2023: Mazda implemented the permanent countermeasure on production MY2024 CX-90 vehicles, which reduced the spring force applied to the worm gear. Excessive spring force caused grease to be pushed out from the gear teeth resulting in lack of oil film. This caused the sticking condition.
December 13, 2023: Mazda continued investigations and confirmed this condition does not cause the steering to lock-up or bind. Furthermore, the driver will feel a momentary increase in effort to steer which feels like a sticky steering condition.
December 22, 2023: Mazda received two additional field reports from the U.S.
January 11, 2024: As momentary sticky steering may cause a loss of vehicle controllability, Mazda judged this condition as impacting vehicle safety. Therefore, Mazda held a Quality Audit Committee meeting to review all available information to date and approved a proactive field action on certain MY2024 CX-90 vehicles.
As of January 11, 2024, Mazda is not aware of any reports of accident or injury related to this concern. Also, as of this date, five field reports have been received by the United States and/or Territory markets.
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
MAZDA | CX-90 | 2024 |
11 Associated Documents
Defect Notice 573 Report
RCLRPT-24V022-8691.PDF 215.328KB
Remedy Instructions and TSB – Repair Procedure
RCRIT-24V022-3736.pdf 2834.217KB
Recall Acknowledgement
RCAK-24V022-1669.pdf 645.341KB
Miscellaneous Document – Warranty Information
RMISC-24V022-1400.pdf 329.544KB
Manufacturer Notices(to Dealers,etc) – Dealer Message re Announcement of Safety Recall 6524A- 2024MY CX-90-Sudden Increase in Steering Effort
RCMN-24V022-3193.pdf 632.327KB
Miscellaneous Document – Chronology of Defect
RMISC-24V022-0415.pdf 89.879KB
Remedy Instructions and TSB – Repair Procedures
RCRIT-24V022-0982.pdf 2882.287KB
Miscellaneous Document – Warranty Information
RMISC-24V022-0254.pdf 757.719KB
Manufacturer Notices(to Dealers,etc) – Dealer Letter re Repair Procedure Update
Remedy Instructions and TSB – Repair Procedure
RCRIT-24V022-1462.pdf 2669.092KB
Miscellaneous Document – Parts and Warranty Information
RMISC-24V022-8059.pdf 517.147KB
Latest Recalls Documents
For the Latest and Most recent Recall Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V022&docType=RCL
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SEOCONTENT-START
WARRANTY INFORMATION
Safety Recall 6524A Safety Recall – 2024 CX-90 – Steering Gear Safety Recall ATTENTION ALL DEALERS: PLEASE READ THE DEALER EMAIL Warranty information will be available 1-24-2024 but may be delayed. If repairing a vehicle:
1. Run the time below (0.8 hours)
2. Replace with parts below
3. Take all (4) required photos from the repair procedure
4. Hold the warranty claim CONDITION OF CONCERN
While driving, the customer may feel a sudden increase of effort when steering the vehicle. Sudden and unexpected change of steering effort while driving may increase the risk of a crash.
A worm gear is incorporated in the steering gear assembly, which transmits the power assist generated by the power steering motor. The worm gear friction force may be excessive which results in increased force required to turn the steering wheel. REPAIR OUTLINE: Dealers will reapply grease to the gear teeth and will replace a spring with an improved part that reduces the spring force to the worm gear in the steering gear assembly. It is expected that the time required to perform this repair is approximately forty (40) minutes. Technicians will be required to take 4 clear photographs of specific steps in the repair and those photographs must be attached to the claim for Recall and Warranty claim review prior to acceptance. SUBJECT VEHICLES
Model Subject VIN range Subject production date range
2024CX-90 JM3 KK **** R1 100044-152900 From December 27, 2022 through
December 11, 2023
*Only the vehicles in this range and with a “Not Launched” or “Open” status in eMDCS are affected. OWNER NOTIFICATION: Mazda will notify the owners by first class mail no later than March 18, 2024. PARTS INFORMATION
Description Part Number Qty Note Scrap
Parts ordering is Yes Recall Parts Kit K1Y0-32-FX8A 1 limited, See
Dealer Email
Campaign Label 9999-95-065A-06 1=50 Obtain in Mazda N/A
labels e-Store
Page 1 of 2 WARRANTY INFORMATION
Safety Recall 6524A WARRANTY CLAIM PROCESSING INFORMATION Steering Gear Repair Kit
Process Number TBD
Symptom Code 99
Damage Code 99
Causal Part Number 1<1 Y0-32-FX8A & 1
& Quantity
Related Part Number TBD ** (see note below) Labor Operation Code TBD
Labor Hours 0.8 hrs.
D40: Photo #1
Required – will be checked by manual claim review
D40: Photo #1
Required – will be checked by manual claim review
D40: Photo #1
Required – will be checked by manual claim review
D40: Photo #1
Required – will be checked by manual claim review
** Related part number will pay 1 /25ᵗʰ of the cost of 0000-77-1217-ES – Tube of Silicone. Each tube will repair 25 cars. RENTAL CAR INFORMATION – TBD
Page 2 of 2
**************************************************************************************************************
Page 1 of 17
REPAIR PROCEDURE
SAFETY RECALL 6524A
Safety Recall – 2024 CX-90 – Steering Gear Safety Recall
A. VEHICLE INSPECTION PROCEDURE-AND PREPERATION FOR REPAIR
1. Verify that the vehicle is within the following ranges and there is a Not Launched or
OPEN 6524A recall in eMDCS:
SUBJECT VEHICLES
Model Subject VIN range Subject production date range
2024CX-90 JM3 KK ****R1 100044-152900
From December 27, 2022 through
December 11, 2023
*Only the vehicles in this range and with a “Not Launched” or “Open” status in eMDCS are affected . .,_
If the vehicle is in the range above and 6524A is OPEN or Not Launched in eMDCS, proceed
to Step 2. If the vehicle does not have an OPEN or Not Launched 6524A campaign, return
the vehicle to the customer or inventory. Not Launched only means the owner letters have
not been sent, the status DOES NOT mean do not repair.
2. Perform an eMDCS Warranty Vehicle Inquiry and inspect the vehicle for a
Campaign Label with 6524A attached to the vehicle’s hood, driver door or
firewall.
NOTE: Always sure to verify the campaign number as the vehicle may have multiple
cam ai n labels on the hood, radiator su ort, firewall or driver door ·amb.
CAMPAIGN LABEL
CAMPAIGN NO:. _
DEAlffi CClJE:. __
DATE: / /
eMDCS – Warranty Vehicle Inquiry Results:
If eMDCS displays: Campaign Label is: Action to perform:
Fill out Dealer Recall Help on OneMazda
If no repair date is displayed on the Present
contact or the Mazda Warranty Department
line with CAMPAIGN 6524A, it has at warrant~der;1t@mazdausa .com to review
not been completed on this vehicle vehicle history.
Not present Proceed to “REPAIR PROCEDURE”.
Present Return vehicle to inventory or customer.
If repair date is displayed for Complete a label and apply to vehicle’s hood with
CAMPAIGN 6524A is “CLOSED” Not present repair date and dealer code from eMDCS
Warranty Inquiry.
CAMPAIGN 6524A is not displayed See Action The vehicle is not affected by Recall 6524A
Page 2 of 17
GENERAL CAUTIONS/WARNINGS – PLEASE READ:
REPAIR PROCEDURE
SAFETY RECALL 6524A
•
Air Bag Connectors and Battery Disconnect: Unless a battery connection or engine
running is required, do not work on the vehicle without disconnecting the vehicle
battery as this could result in damage to the vehicle or safety systems.
Customer Personal Items: If personal belongings need to be removed from vehicle interior
trunk area or inside, please remember to neatly replace any customer items in the same location
after the repair is completed. If items need to be removed, please kindly ask the customer to
remove prior to beginning work on the vehicle.
Damage to interior or exterior: Care should be taken, and protective cover(s) used when
working on any Mazda vehicle. Damage to any components, interior trim, vehicle accessories,
body panels and paint will not be reimbursed by Mazda {including OEM or aftermarket).._
All of these items above could delay repairs, compromise safety, as well as negatively
affect the customer experience and Mazda dealer-customer relationship.
B. REPAIR PROCEDURE
• 1. Four photos are required for the warranty claim. Make sure to take all four
(4) photos during the repair.
2. Obtain the correct recall part from your parts department: Mazda PN#
K1Y0-32-FX8A
Tools Required
Torque Wrench, in-lb and ft-lb
Plastic pry tool
10mm box end wrench
10mm Hex/ Allen Socket
1 / 4 or 3 / 8 Ratchet
6-7 inch Ratchet extension
Neoprene Gloves
Page 3 of 17
Parts Kit Contents: K1 Y0-32-FX8A
REPAIR PROCEDURE
SAFETY RECALL 6524A
CAUTION: Do not handle parts in this campaign with bare hands, always use Neoprene gloves
when handling all parts.
1. O-ring
2. 2 new 10mm bolts
3. Outer Cap
4. Plastic strips (2)
5. Pink grease for new nut, spring and cap
6. Inner Cap
7. Spring (All Black in Color)
Page 4 of 17
.
REPAIR PROCEDURE
SAFETY RECALL 6524A
1 Leave Hood Closed. Lift Vehicle and remove the #3 front engine cover, do not remove covers
#1 and #2. Follow steps in MGSS for removal. Refer to MGSS online (FRONT UNDER COVER# 3
REMOVAL/ INSTALLATION)
Step Part name
1 Bolt
2 Fastener
3 Front undercover No.3
Engine Cover
#3
Applicable
condition
All models
All models
All models
Tightening torque
95 lbf-in (11 N·m)
–
–
1. In order to prevent contamination later in the procedure, (step 4), wash away with water,
any slush, snow, sand, mud, etc. around the steering gear and dry the entire area with an
air gun (Figure A). Use Parts Cleaner if needed to completely clean the area to avoid any
contamination.
X
Page 5 of 17
Ⓓ Ⓒ Ⓑ
Ⓔ
Ⓐ
REPAIR PROCEDURE
SAFETY RECALL 6524A
2. Loosen the two bolts for the black cover (Figure B) on the top of the steering motor to the
point where the threads are visible by roughly 1 / 8″ (3 mm).
1
3. Gently use a plastic door trim tool to remove the black cover so that it slowly pops up and
rests against the loosened bolts (Figure C). You will need to gently insert the pry tool
several times rocking the piece slowly up left-to-right (A), (B), (C), (D), and (E). Do not
use any excessive force. (Figure D). There is an O-Ring on this cover that makes it difficult
to remove by hand. PLEASE CLICK HERE TO WATCH THE VIDEO OF THIS PROCEDURE
STEP.
•
Do not use a metal pry tool or flathead screwdriver, as this will cause damage/ deform
the aluminum case. Deformation or cracking of the black cover will allow moisture
to enter the worm gear breaking down the grease resulting in rusted parts. Costs to
replace damage to these components caused by incorrect tool use /improper repair
will be absorbed by the Mazda dealer causing customer frustration and delay of
repairs.
Figure D
Figure C
Page 6 of 17
REPAIR PROCEDURE
SAFETY RECALL 6524A
4. Once the cover ha~ been loosened and i~ against the bolt.~, remove both bolt.~ and remove
the cover by hand. It does not take much force with the tool to pop up the cover.
5. \:VASI I YOUR I IANDS COMPL[T[l Y A \JD DRY Tl ICM. Take out the plastic plate in the
r”pl;i1;t,me11 I p.irl> ki L and pl;i(,e i L on il de.i11 doth ( H!!,ure ~ l. u~e il LI em1 \Jeopre11″ !!,love.
6. Using your gloved finger. press the grease into the g.:ip between the. ,1luminum case and the
worm gear insert around the worm gear rigure G, which adheres to the area of the blue
rraml:’ in Fig,ure H. f\ote G is showing, a Righi H,u1d Drive Steering, Rack.
BEFORE
Figuni H
Page 7 of 17
2
1
3
a. Flow of pushing grease into the gap is below
REPAIR PROCEDURE
SAFETY RECALL 6524A
CAUTION: Do not push grease in with your bare hands! If you work with your bare
hands, dirt and foreign matter will get inside, which can result in poor steering
performance or binding of the steering gear. PLEASE CLICK HERE TO WATCH THE
VIDEO OF THIS PROCEDURE STEP.
Push the protruded grease (pink) (1) into the gap between the worm wheel (2) and the housing
(3) with a finger covered with the new glove as per the following image.
NOTE: There are variations in the amount of the grease attached to the worm wheel. Even
if the amount is small, perform this procedure.
7. Place the plastic plate between the aluminum case and the worm gear, align the range of
the blue frame in the figure below twice on the left and right, and press the pink grease on
the groove part of the gear.
Page 8 of 17
REPAIR PROCEDURE
SAFETY RECALL 65 24A
When you are done this is what this looks like. You can see that the plastic tool has
pushed the grease into the teeth of the gear.
AFTER PRESSING GREASE IN
8. PHOTO REQUIREMENT #1 and 2: Write the RO# on the Steering Gear Case.
Take two photos, one with pink grease blended into the gear teeth and the other with
the RO in the photo and RO on the gear case The photos must be taken properly, or the
warranty claim will not be approved. Make sure it is clear like the below as this will be
100% reviewed.
PHOTO #1
PHOTO #2
Page 9 of 17
9. Discard the plastic plate used to press in the grease.
10. O-Ring removal and Cover cleaning:
REPAIR PROCEDURE
SAFETY RECALL 6524A
a. Figure J. Remove the O-ring in Figure J on the outer periphery of the black cover and
discard the O-ring.
b. Figure K. Place the black cover on a clean cloth and clean the housing contact surface of
the aluminum case with a non-corrosive parts cleaner that does not degrade plastic or
metal.
c. Figure L. Thoroughly remove dirt from the O-ring groove with a parts cleaner. Install the
new O-ring in the parts kit.
Figure J
PLACE GREASE ON THE ENTIRE O-RING
11. Install the black cover, but do not push down completely. Leave a gap and insert the bolts
a few turns holding the black cover in place. Refer to Figure L.
Figure L
Gap in cover
Page 10 of 17
A:
TIGHTEN
REPAIR PROCEDURE
SAFETY RECALL 6524A
12. Gently push the black cover into the aluminum case housing surface (Figure M) and tighten
the bolts with the specification below (Figure N).
Figure M I
Black cover bolts Tightening torque
A 6-7Ibf-ft (8 – 10) N-m
13. Replacement: Use a Tl 0 hex wrench to remove the end cap in Figure 0 .
Page 11 of 17
OK
NG
REPAIR PROCEDURE
SAFE.TY RECALL 6524A
14. Clean off a medium or long needle nose pliers and remove the spring and/ or cap inside if
needed. The tool must be cleaned to prevent any contamination.
Visually inspect the inside and make sure that there are no springs and caps.
Correct – Normal condition: After spring and cap are removed.
NO GOOD – Incorrect condition: Spring i~ nol removed
Page 12 of 17
NG
NO GOOD (NG) – Incorrect condition: Cap is not removed
REPAIR PROCEDURE
SAFETY RECALL 6524A
15. Remove all of the sealer on the end cap mounting surface. Use a new clean glove to
remove the gray sealer applied to the threaded part of the end cap mounting surface.
Remove any remaining sealer, with a clean rag and parts cleaner as necessary. by inserting
it into the end cap attachment part and removing the sealant from right to left.
CAUTION: Do not rotate to the right. If you rotate it to the right, the sealer might get
pushed into the housing.
Before cleanin After cleanin
Page 13 of 17
➢ Position and direction of the spring and spring seat
Good No Good
—
The spring seat is placed
upside down.
The spring and the spring
seat are reversed.
cap
spring
End Cap
REPAIR PROCEDURE
SAFETY RECALL 6524A
16. Take out the cap, spring, end cap, and grease from the replacement parts kit and replace
into the hole. Apply the grease to both ends of the spring and the tip of the cap. Grease is
applied to prevent parts from falling during installation. NOTE: Wire Diameter is smaller.
Old Sprin Color: Half White Coil
………..
Page 14 of 17
17. PHOTO REQUIREMENT #3: Take a photo for the warranty claim.
REPAIR PROCEDURE
SAFETY RECALL 6524A
With the RO# in the photo, take a photo so that the integrated cap, spring, end cap, and
old spring, which are replacement parts, are in the photo. (Note, this photo is a little low
and you do not see the RO# on the rack. Make sure the RO# is present in the photo like #4
18. After taking photo #2, start the threads of the integrated cap, spring, and end cap (should
be a roximatel 2 turns).
19. Apply a silicone liquid gasket (0000-77-1217-ES Mazda required sealant) to the thread of
the end cap and tighten it. This tube will repair at least 25 vehicles. PLEASE CLICK HERE TO
WATCH THE VIDEO OF THE PROCEDURE. NOTE: THE SEALANT IS GRAY IN COLOR FROM
PN# 0000-77-1217-ES)
Page 15 of 17
Tightening torque: 9-12 lbf-ft ( 12-16 N-m)
BEFORE TORQUE WITH GREASE AFTER TORQUE
20. PHOTO REQUIREMENT #4. Take a photo for a warranty claim.
Take a photo so that the black cover and end cap are visible.
REPAIR PROCEDURE
SAFETY RECALL 6524A
NOTE: THE RO ON THE CASE MUST MATCH THE RO IN THE PHOTO, THIS
WILL BE CHECKED.
Page 16 of 17
REPAIR PROCEDURE
SAFETY RECALL 6524A
21. Reinstall the #3 Under Cover. Refer to MGSS online {FRONT UNDER COVER# 3 REMOVAL /
INSTALLATION)
y
2 1 2
azzdjw00000584
Step Part name Applicable Tightening torque
condition
1 Bolt All models 11 N·m {110 kgf·cm, 95 in·lbf}
2 Fastener All models –
3 Front undercover No.3 All models –
Page 17 of 17
➢
➢
22. Steering operation check:
a. Lower the vehicle to approximately 1 ft from the ground, on the lift
REPAIR PROCEDURE
SAFETY RECALL 6524A
b. Push the start button to the IG-ON position (engine does not start/ PHEV is not
Ready- ON)
c. Make one full steering wheel revolution, from full left to full right, lock-to-lock
d. Follow the flow chart to make sure that there is no binding in the steering wheel
From lock-to-lock, is the steering wheel
binding or heavy?
Move to step 23.
Go back to step 13-16 and check
the spring is replaced. Make sure
the cap is in place and the new
spring is installed, with grease.
If the steering is binding or heavy when turning the steering wheel :
– Check if the removed spring is outside half white.
– Check if the pushing grease procedure has been done properly.
If steering wheel is heavy to turn:
Verify that there the spring seat is removed. Steering wheel becomes heavy if the old
spring seat remains in the housing.
23 . Place the vehicle on the ground, and open the hood. Move to Section C. Campaign
Label Replacement.
C. CAMPAIGN LABEL INSTALLATION
a. Fill out a Black “Campaign Label” (9999-95-0SSA-06) with Campaign#: “6524A”,
your dealer code, and the repair date.
CAMP IGN LABEL
CAMPAIGN NO:~–
DEAlER COOE: __ _
DATE / /
b. Affix it to the hood as shown. If you cannot place the label here, the radiator
support, firewall or driver door jamb are acceptable locations:
END OF REPAIR PROCEDURE
**************************************************************************************************************
MAZDA D • ALER • MAIL
January 22, 2024
Attention: Mazda General, Parts and Service Managers Subject: Announcement of Safety Recall 6524A- 2024MY CX-90-Sudden Increase in Steering Effort Dear Mazda Dealer Partners, Mazda Motor Corporation has decided to conduct a Safety Recall on certain 2024MY CX-90 vehicles. Please see the description, model, year, and VIN range below for the vehicles in this campaign. There are 43,695 vehicles affected with this concern in the US. SPECIAL REQUEST TO DEALER PARTNERS: For this recall and all safety recalls for Mazda vehicles, it is highly recommended that the General Manager, Service Manager, and Shop Foreman (if applicable) meet with all technicians and remind everyone that the recall instructions must be read thoroughly and
performed exactly as they are written. Improper repairs caused by not reading instructions can lead to
incomplete repairs and put customers at risk when driving their vehicles.
Subject Vehicles:
Model I Subject VIN range I Subject production date range
From December 27, 2022, through
December 11, 2023 2024CX-90 JM3 KK ******100044-152900 Note: All powertrain types are affected (MHEV/PHEV) *Only the vehicles in this range and with a “Not Launched or Open” status in eMDCS are affected. Concern Outline: While driving, the customer may feel a sudden increase of effort when steering the vehicle. Sudden and unexpected change of steering effort while driving may increase the risk of a crash. A worm gear is incorporated in the steering gear assembly, which transmits the power assist generated by the power steering motor. The worm gear friction force may be excessive which results in increased force required to turn the steering wheel. Suspension of Delivery – Mazda Dealer Action Requested:
Currently, there are approximately 10,954 CX-90 vehicles in dealer inventory or in transit to dealers. All Mazda dealers must quarantine any affected new, used, or Certified Preowned Owned (CPO) in-stock vehicle until the repair is completed. The affected dealer inventory list is available on Mazda Global Service Support (MGSS) and was provided to your District Service Manager. The current inventory list will be updated weekly or bi-weekly on MGSS as needed. Repair Outline: Dealers will reapply grease to the gear teeth and will replace a spring with an improved part that reduces the spring force to the worm gear in the steering gear assembly. This repair was validated at MNAO and there is ample time provided for this recall to complete the repair and take the required photos. Technicians will be required to take 4 clear photographs of specific steps in the repair and those photographs must be attached to the claim for Recall and Warranty claim review prior to acceptance. NOTE: As a reminder, failure to properly perform any recall repair is a direct violation of Paragraph 14(F) of the Dealer Agreement and can cause one or more of the following: Mechanical breakdown or failure, crash or injury, Dealership penalties/fines by Mazda and NHTSA, increased liability risk for the dealership, Missed Recall penalties, loss of customer trust, and a poor Customer Experience. Additionally, vehicles sold by Mazda Canada, Inc. and U.S. Territories are also affected by this recall and should be repaired if presented to your dealership. Parts: A limited number of repair kits containing grease, a tool, a spring and the other required parts is available, and a push shipment of kits is being sent to all dealers with affected inventory. Orders for additional kits are not available at this time. We anticipate before the end of January, a second push shipment will be sent to dealers as additional kits and vehicles arrive. By mid to late February additional orders will be available from the Limited Parts Ordering screen in eMDCS. For proper parts supply planning, a copy of the UIO by dealer will also be made available to your field management team. Mazda Employee Lease/Corporate Vehicles: If you are a Mazda employee responsible for or driving a 2024 CX-90, the Mazda Recall Team will contact the person assigned to the vehicle directly by email when the repair is available. Instructions will be provided on where you can take the vehicle (a Mazda Dealer or Mazda Service Facility). If you have any concerns with your 2024 CX-90, please visit a Mazda dealer or contact your corporate/regional vehicle coordinator. Owner Notification: All vehicles will show as “Not Launched” on January 22, 2024, by the end of the business day. The “Not Launched” status is required prior to mailing Owner Letters to customers, but this status does not mean do not repair. In stock vehicles showing “Not Launched” status must be repaired prior to customer delivery when parts are available. If the campaign is not complete, the vehicle cannot be delivered to a customer. Please read this entire email and check MGSS under this recall for updated instructions. Mazda will directly contact affected owners by U.S. Mail no later than March 18, 2024. To help you effectively perform this recall, Mazda has developed the following resources: 1. Parts and Warranty Information, Repair Procedure, and the affected VIN list are expected to be posted to MGSS on or before January 24, 2024, but may be delayed. When posted, searching by VIN is available immediately, but Keyword Searching may not be available until the next business day.
2. For Warranty questions, please contact the Warranty Hotline at warrantydept@mazdausa.com
3. For parts questions, contactthe Corporate Dealer Assistance Group at corpdag@mazdausa.com or by calling (877) 727-6626 Option 2
4. For recall related questions, please fill out the Dealer Recall Help Form located on OneMazda. 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 are greatly appreciated. Sincerely, Mazda North American Operations Travis Young
Manager, Recalls Technical Services Division
M;\Z DA NORTH i\,”1E RICAN OPE RAT 10,
**************************************************************************************************************
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-022
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Mazda North American Operations JAN 18, 2024 NHTSA Recall No. : 24V-022 Manufacturer Recall No. : 6524A Manufacturer Information :
Manufacturer Name : Mazda North American Operations Address : 1025 Connecticut Avenue, NW
Suite 910 Washington DC 20036
Company phone : 800-222-5500 Population :
Number of potentially involved : 43,752 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2024-2024 MAZDA CX-90
Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : GAS
Descriptive Information : The following is the affected number of vehicles by MY/Make/Model:
MY2024 Mazda CX-90 built at Mazda Motor Corporation in Japan: 43,752 units.
– Recall population determined by the production record of vehicles equipped with the subject steering gear assembly at Mazda Motor Corporation.
– Vehicles not included in the recall have the improved steering gear assembly.
Production Dates : DEC 27, 2022 – DEC 11, 2023 VIN Range 1 : Begin : JM3KKEHD6R1100044 End : JM3KKCHD1R1152900 ✔ Not sequential Description of Defect :
Description of the Defect : While driving, the customer may feel a sudden increase of effort when steering the vehicle.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Sudden and unexpected change of steering effort while driving may increase risk of a crash.
Description of the Cause : A worm gear is incorporated in the steering gear assembly, which transmits the power assist generated by the power steering motor.
The worm gear friction force may be excessive which results in increased force required to turn the steering wheel. Identification of Any Warning
that can Occur : Part 573 Safety Recall Report 24V-022 Page 2 Involved Components : Component Name 1 : GEAR STEERING Component Description : Steering gear and linkage Component Part Number : KJK8-32-110 Supplier Identification : Component Manufacturer
Name : Hitachi Astemo, Ltd.
Address : 2459-1 Jinba,
Gotemba-Shi, Shizuoka Prefecture Foreign States 412-0047 Country : Japan Chronology :
Please see a Chronology report attached. Description of Remedy :
Description of Remedy Program : Owners will be notified by mail and instructed to take their vehicle to a
Mazda dealer.
Dealers will replace the spring engaging the worm gear with an improved part and will also reapply grease to the gear teeth. There will be no charge for this service to vehicle owners.
Any repairs related to this defect in the subject vehicles would have been covered under Mazda’s new vehicle warranty period. Therefore, a reimbursement plan for repairs made in connection with this defect prior to notification is not being offered to affected vehicle owners. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : The remedy component reduces the spring force to the worm gear in the steering assembly.
The improved steering gear assembly was implemented on December 11, 2023, at the vehicle assembly plant in Japan. Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on or before January 23, 2024. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-022
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Mailing of owner notification letters is expected to be completed on or before March 18, 2024.
Planned Dealer Notification Date : JAN 23, 2024 – JAN 23, 2024
Planned Owner Notification Date : MAR 18, 2024 – MAR 18, 2024
* NR – Not Reported
**************************************************************************************************************
SPECIAL REQUIRMENT
Steering gear is a strictly controlled part, that is being monitored. You must attach one photo described below when submitting the recall claim. A claim without attaching the photo will be rejected, denied, or debited. PHOTO REQUIREMENT:
Attach one photo to the warranty claim.
NOTE: Photo must show the RO# of the vehicle repaired. See photo example: Take a photo so that the new integrated cap, spring, end cap are ready to be installed, and old spring which will be discarded are all visible.
Make sure the RO# written on the rack is present in the photo. ing
properly
d Old Spring White Clearly seen and ready for discard PARTS INFORMATION
Description Part Number Quantity Note Components:
Coil spring kit K1Y0-32-FX8A 1 Spring (1 pc), End cap (1 pc), Spring
seat (1 pc), Grease (1g), Flange bolt (2 pcs), O-ring (1 pc), Spatula (2 pcs)
One tube of silicone will repair a Liquid gasket 0000-77-1217-ES As minimum of 25 vehicles. Therefore Qty
(do not use this required of 1 will not be charged out on the
PN# for claim) repair order
Campaign Label 9999-95-065A-06 1=50 Obtain in Mazda e-Store
labels Page 2 of 3 WARRANTY CLAIM PROCESSING INFORMATION
Grease reapplication and Steering gear coil spring replacement
Process Number AR001A
Symptom Code 99
Damage Code 99
Causal Part Number and Qty 1<1 Y0-32-FX8A & 1
Related Part Number and Qty 5555-SE-001 & 1 Labor Operation Number XXWL3XRX
Labor Hours 0.8 hrs.
D40: Photo Required photo from repair procedure
One tube of silicone will repair at least 25 vehicles. This part# represents 1 /25th of the dealer cost of a tube.
Note: Please be sure to attach one photo, as per the Special Requirement, to every warranty claim. A claim without attaching the photo will be rejected, denied, or debited.
RENTAL CAR INFORMATION
Rental expenses exceeding the two-day limit or over the per day limit set by Mazda Warranty policy will require prior Warranty Department Authorization prior to giving the rental to the customer regardless of the reason. Please refer to the Mazda Rental Car Reimbursement Program policy in the Mazda Warranty Policies and Procedures Manual. 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, so the next customer can receive the same experience. Rental Car Warranty Claim Information
MCVP Vehicle Preferred Rental Agency Vehicle
Warranty Type Code A
Symptom Code 99
Damage Code 99
Part Number Main Cause 5555-65-24AR
Part Quantity 0
Labor Operation Code MM024XRX
Labor Hours N/A 0
Sublet- Rental Car
Sublet Invoice MCVP does not require claim Number from Rental Invoice Number submission or Dealer Purchase Order Sublet Type Code Enter “Z9” ( other)
Sublet Amount Up to $30.00 per day for
the number of days customer had rental car
Sublet Text Number of days rental car
was supplied to customer Page 3 of 3
**************************************************************************************************************
Reference illustration/photo
(RHD vehicle)
Steering gear assembly
Spring Worm gear Reduction gear
Worm wheel
Inside of Reduction Gear WARRANTY INFORMATION
Safety Recall 6524A SPECIAL REQUIRMENT
Steering gear is a strictly controlled part, that is being monitored. You must attach all four (4) photos described below when submitting the recall claim. A claim without attaching these four (4) different photos will be rejected, denied, or debited. NOTE: Photos 2-4 must show the RO# of the vehicle repaired. Photo #1 and #2 with the condition after pushing the grease into the gap. Steering Rack must have RO# written on it and in frame except photo #1 as it is too difficult to take one photo showing both requirements. Note paperless dealers or to save printing costs do not have to have the RO in frame just the written RO# on the steerin rack. Photo #3 with the pre-assembled new parts and the removed old spring. NOTE: This photo was a bit low and is missing the written RO#. Make sure it is visible as in Photo #4. Photo #4 of completed steering gear housing with the black cover. Note the added silicone sealant is on the end cap nut. Note paperless dealers or to save printing costs do not have to have the RO in frame just the written RO# on the steering rack. Page 2 of 4 WARRANTY INFORMATION
Safety Recall 6524A PARTS INFORMATION Description Part Number Quantity Components: Note Coil spring kit Liquid gasket Campaign Label 1<1 Y0-32-FX8A 0000-77-1217-ES
(do not use this PN# for claim)
9999-95-065A-06 1 As required 1=50
labels Spring (1 pc), End cap (1 pc), Spring seat (1 pc), Grease (1g), Flange bolt (2 pcs), O-ring (1 pc), Spatula (2 pcs) One tube of silicone will repair a minimum of 25 vehicles. Therefore Qty of 1 will not be charged out on the repair order Obtain in Mazda e-Store WARRANTY CLAIM PROCESSING INFORMATION NOTE: Paperless dealers: RO in 2ⁿᵈ and 4ᵗʰ photo is NOT Required, but writing the RO# on the steering gear 1s st1·11 req.uired. Process Number Symptom Code Damage Code
Causal Part Number and Qty
Related Part Number and Qty Labor Operation Number Labor Hours
D40: Photo #1
D40: Photo #2
D40: Photo #3
D40: Photo #4
1<1 Sublet- Towing (if needed) Grease reapplication and Steering gear coil spring replacement
AR001A 99
99
1<1 Y0-32-FX8A & 1
5555-SE-001 & 1**
XXWL3XRX
0.8 hrs.
Required photo from repair procedure Required photo from repair procedure Required photo from repair procedure Required photo from repair procedure
Warranty Pre-auth required and must follow warranty guidelines and reason RSA could not be used. **one tube of silicone will repair at least 25 vehicles. This part# represents 1 /25th of the dealer cost of a tube. Note: – Please be sure to attach the four (4) photos, as per the Special Requirement, to every warranty claim. A claim without attaching these four (4) different photos will be ejected, denied, or debited. Paperless dealers: RO in 2ⁿᵈ and 4ᵗʰ photo is NOT Required, but writing the RO# on the steering gear is still required. Page 3 of 4 RENTAL CAR INFORMATION
WARRANTY INFORMATION
Safety Recall 6524A
Rental expenses exceeding the two-day limit or over the per day limit set by Mazda Warranty policy will require prior Warranty Department Authorization prior to giving the rental to the customer regardless of the reason. Please refer to the Mazda Rental Car Reimbursement Program policy in the Mazda Warranty Policies and Procedures Manual. 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, so the next customer can receive the same experience. Rental Car Warranty Claim Information Warranty Type Code Symptom Code Damage Code
Part Number Main Cause Part Quantity
Labor Operation Code
Labor Hours Sublet- Rental Car Sublet Invoice Number
Sublet Type Code Sublet Amount Sublet Text MCVP Vehicle Preferred N/A MCVP does not require claim submission Rental Agency Vehicle
A 99 99 5555-65-24AR
0 MM024XRX 0 Number from Rental Invoice or Dealer Purchase Order Enter “Z9” ( other)
Up to $30.00 per day for the number of days customer had rental car
Number of days rental car was supplied to customer
Page 4 of 4
**************************************************************************************************************
Page 1 of 17
REPAIR PROCEDURE
SAFETY RECALL 6524A
Safety Recall – 2024 CX-90 – Steering Gear Safety Recall
A. VEHICLE INSPECTION PROCEDURE-AND PREPERATION FOR REPAIR
1. Verify that the vehicle is within the following ranges and there is a Not Launched or
OPEN 6524A recall in eMDCS:
SUBJECT VEHICLES
Model Subject VIN range Subject production date range
2024CX-90 JM3 KK ****R1 100044-152900
From December 27, 2022 through
December 11, 2023
*Only the vehicles in this range and with a “Not Launched” or “Open” status in eMDCS are affected . .,_
If the vehicle is in the range above and 6524A is OPEN or Not Launched in eMDCS, proceed
to Step 2. If the vehicle does not have an OPEN or Not Launched 6524A campaign, return
the vehicle to the customer or inventory. Not Launched only means the owner letters have
not been sent, the status DOES NOT mean do not repair.
2. Perform an eMDCS Warranty Vehicle Inquiry and inspect the vehicle for a
Campaign Label with 6524A attached to the vehicle’s hood, driver door or
firewall.
NOTE: Always be sure to verify the campaign number as the vehicle may have multiple
cam ai n labels on the hood, radiator su ort, firewall or driver door ·amb.
CAMPAIGN LABEL
CAMPAIGN NO:. _
DEAlffi CClJE:. __
DATE: / /
eMDCS – Warranty Vehicle Inquiry Results:
If eMDCS displays: Campaign Label is: Action to perform:
Fill out Dealer Recall Help on OneMazda
If no repair date is displayed on the Present
contact or the Mazda Warranty Department
line with CAMPAIGN 6524A, it has at warrant~der;1t@mazdausa .com to review
not been completed on this vehicle vehicle history.
Not present Proceed to “REPAIR PROCEDURE”.
Present Return vehicle to inventory or customer.
If repair date is displayed for Complete a label and apply to vehicle’s hood with
CAMPAIGN 6524A is “CLOSED” Not present repair date and dealer code from eMDCS
Warranty Inquiry.
CAMPAIGN 6524A is not displayed See Action The vehicle is not affected by Recall 6524A
Page 2 of 17
GENERAL CAUTIONS/WARNINGS – PLEASE READ:
REPAIR PROCEDURE
SAFETY RECALL 6524A
•
Air Bag Connectors and Battery Disconnect: Unless a battery connection or engine
running is required, do not work on the vehicle without disconnecting the vehicle
battery as this could result in damage to the vehicle or safety systems.
Customer Personal Items: If personal belongings need to be removed from vehicle interior
trunk area or inside, please remember to neatly replace any customer items in the same location
after the repair is completed. If items need to be removed, please kindly ask the customer to
remove prior to beginning work on the vehicle.
Damage to interior or exterior: Care should be taken, and protective cover(s) used when
working on any Mazda vehicle. Damage to any components, interior trim, vehicle accessories,
body panels and paint will not be reimbursed by Mazda {including OEM or aftermarket).._
All of these items above could delay repairs, compromise safety, as well as negatively
affect the customer experience and Mazda dealer-customer relationship.
B. REPAIR PROCEDURE
• 1. Four photos are required for the warranty claim. Make sure to take all four
(4) photos during the repair.
2. Obtain the correct recall part from your parts department: Mazda PN#
K1Y0-32-FX8A
Tools Required
Torque Wrench, in-lb and ft-lb
Plastic pry tool
10mm box end wrench
10mm Hex/ Allen or M 12 Triple Square Socket
1 / 4 or 3 / 8 Ratchet
6-7 inch Ratchet extension
Neoprene Gloves
Page 3 of 17
Parts Kit Contents: K1 Y0-32-FX8A
REPAIR PROCEDURE
SAFETY RECALL 6524A
CAUTION: Do not handle parts in this campaign with bare hands, always use Neoprene gloves
when handling all parts.
1. O-ring
2. 2 new 10mm bolts
3. Outer Cap
4. Plastic strips (2)
a. 1 strip to be used for repair
b. 1 extra strip included if first strip is lost/misplaced/becomes dirty prior to use.
5. Pink grease for new nut, spring and cap only ** DO NOT INSTALL IN LARGE WORM GEAR
6. Inner Cap
7. Spring (All Black in Color)
Page 4 of 17
.
REPAIR PROCEDURE
SAFETY RECALL 6524A
1 Leave Hood Closed. Lift Vehicle and remove the #2 front engine cover, do not remove covers
#1 and #2. Follow steps in MGSS for removal. Refer to MGSS online {FRONT UNDER COVER# 3
REMOVAL/ INSTALLATION)
Step Part name
1 Bolt
2 Fastener
3 Front undercover #2
Engine Cover
#2
Applicable
condition
All models
All models
All models
Tightening torque
95 lbf-in (11 N-m)
–
–
1. In order to prevent contamination later in the procedure, (step 4), wash away with water,
any slush, snow, sand, mud, etc. around the steering gear and dry the entire area with an
air gun (Figure A). Use Parts Cleaner if needed to completely clean the area to avoid any
contamination.
Page 5 of 17
Ⓓ Ⓒ Ⓑ
Ⓔ
Ⓐ
REPAIR PROCEDURE
SAFETY RECALL 6524A
2. Loosen the two bolts for the black cover (Figure B) on the top of the steering motor to the
point where the threads are visible by rou hly 1 / 8″ (3 mm).
1
3. Gently use a plastic door trim tool to remove the black cover so that it slowly pops up and
rests against the loosened bolts (Figure C). You will need to gently insert the pry tool
several times rocking the piece slowly up left-to-right (A), (B), (C), (D), and (E). Do not
use any excessive force. (Figure D). There is an O-Ring on this cover that makes it difficult
to remove by hand. PLEASE CLICK HERE TO WATCH THE VIDEO OF THIS PROCEDURE
STEP. (Right Hand drive vehicle shown, but repair is the same)
•
Do not use a metal pry tool or flathead screwdriver, as this will cause damage/ deform
the aluminum case. Deformation or cracking of the black cover will allow moisture
to enter the worm gear breaking down the grease resulting in rusted parts. Costs to
replace damage to these components caused by incorrect tool use /improper repair
will be absorbed by the Mazda dealer causing customer frustration and delay of
repairs.
Figure D
Figure C
Page 6 of 17
REPAIR PROCEDURE
SAFETY RECALL 6524A
4. Once the cover has been loosened and is against the bolts, remove both bolts and remove
the cover by hand. It does not take much force with the tool to pop up the cover.
5, WASH YOUR HANDS COMl’L~l~LY AND DRY IH~M. lak.e oul om~ pla,Lil ,Lriμ in Lhe
replacement parts kit ;md pl;ic.e it on ;i clean cloth (Figure F). lJse a clean ‘-Jeoprene glove.
If the first strip is lost or has debris from the shop environment, use the second strip.
6. Using. your glowd finger, press Lhe g.re.Jse inLo the g,,p between the Jlwnimun case and the
worm gear insert around the worm gear Figure G, which adheres to the area of the blue
rra rne in Hgure H. I\ ole <.; is showing a Righ L Hand Drive Sleering Ra(,k,
B[FOR[
Figure H
Page 7 of 17
2
1
3
a. Flow of pushing grease into the gap is below
REPAIR PROCEDURE
SAFETY RECALL 6524A
CAUTION: Do not use grease from parts kit, and do not push grease in with your bare
hands! If you work with your bare hands, dirt and foreign matter will get inside, which
can result in poor steering performance or binding of the steering gear. PLEASE CLICK
HERE TO WATCH THE VIDEO OF THIS PROCEDURE STEP. (Right Hand drive car is
shown, but repair is the same)
Push the protruded grease (pink) (1) into the gap between the worm wheel (2) and the housing
(3) with a finger covered with the new glove as per the following image.
NOTE: There are variations in the amount of the grease attached to the worm wheel. Even
if the amount is small, perform this procedure.
7. Place the plastic strip between the aluminum case and the worm gear, align the range of the
blue frame in the figure below twice on the left and right, and press the pink grease on the
groove part of the gear.
When you are done this is what this looks like. You can see that the plastic strip has
pushed the grease into the teeth of the gear.
Page 8 of 17
100%
AFTER PRESSING GREASE IN
REPAIR PROCEDURE
SAFETY RECALL 6524A
8. PHOTO REQUIREMENT #1 and 2: Write t he RO # on the Steering Gear Case .
Take two photos, one w ith pink grease blen ded into the gear teeth and the othe r with th e RO in
the photo and RO on the gea r case The photos must be t aken p roperly, or the warranty cla i m will
n ot be approved. Make sure it is c lear like the below as thi s will be 100% revie wed .
NOTE: Paperless dealers: RO in 2 nd photo is NOT Required to save printing costs but write the
RO on the steering gear.
PHOTO #1
PHOTO #2
‘ ..
9. Discard the plastic strip used t o press in the grease.
NOTE: Paperless dealers: RO in
second photo is NOT Required to save
printing costs, but write the RO # on
the steering gear.
Page 9 of 17
10. O-Ring removal and Cover cleaning:
REPAIR PROCEDURE
SAFETY RECALL 6524A
a. Figure J. Remove the O-ring in Figure J on the outer periphery of the black cover and
discard the O-ring.
b. Figure K. Place the black cover on a clean cloth and clean the housing contact surface of
the aluminum case with a non-corrosive parts cleaner that does not degrade plastic or
metal.
c. Figure L. Thoroughly remove dirt from the O-ring groove with a parts cleaner. Install the
new O-ring in the parts kit.
Figure J
PLACE GREASE ON THE ENTIRE O-RING
11. Install the black cover, but do not push down completely. Leave a gap and insert the bolts
a few turns holding the black cover in place. Refer to Figure L.
Figure L
Page 10 of 17
A:
TIGHTEN
REPAIR PROCEDURE
SAFETY RECALL 6524A
12. Gently push the black cover into the aluminum case housing surface (Figure M) and tighten
the bolts with the specification below (Figure N).
Figure M I
Black cover bolts Tightening torque
A 6-7Ibf-ft (8 – 10) N-m
13. Replacement: Use a Tl 0 hex wrench to remove the end cap in Figure 0 .
Page 11 of 17
OK
NG
NG
REPAIR PROCEDURE
SAFETY RECALL 6524A
14. Clean off a medium or long needle nose pliers and remove the spring and/ or cap inside if
needed. The tool must be cleaned to prevent any contamination.
Visually inspect the inside and make sure that there are no springs and caps.
Correct – Normal condition: After spring and cap are removed.
NO GOOD – Incorrect condition: Spring is not removed
NO GOOD (NG)- Incorrect condition: Cap is not removed
15. Remove all of the sealer on the end cap mounting surface. Use a new clean glove to
Page 12 of 17
REPAIR PROCEDURE
SAFETY RECALL 6524A
remove the gray sealer applied to the threaded part of the end cap mounting surface.
Remove any remaining sealer, with a clean rag and parts cleaner as necessary. by inserting
it into the end cap attachment part and removing the sealant from right to left.
CAUTION: Do not rotate to the right. If you rotate it to the right, the sealer might get
pushed into the housing.
Before cleanin After cleanin
16. Take out the cap, spring, end cap, and grease from the replacement parts kit and replace
into the hole. Apply the grease to both ends of the spring and the tip of the cap. Grease is
applied to prevent parts from falling during installation. NOTE: Wire Diameter is smaller.
Old Sprin Color: Half White Coil
Page 13 of 17
➢ Position and direction of the spring and spring seat
Good No Good
—
The spring seat is placed
upside down.
The spring and the spring
seat are reversed.
cap
spring
End Cap
REPAIR PROCEDURE
SAFETY RECALL 6524A
Where to place Grease
◄
… ………….. .. ………….
17. PHOTO REQUIREMENT #3: Take a photo for the warranty claim.
With the RO# in the photo, take a photo so that the integrated cap, spring, end cap, and
old spring, which are replacement parts, are in the photo. (Note, this photo is a little low
and you do not see the RO# on the rack. Make sure the RO# is present in the photo like #4
Page 14 of 17
REPAIR PROCEDURE
SAFETY RECALL 6524A
18. After taking photo #3, start the threads of the integrated cap, spring, and end cap (should
be approximately 2 turns).
19. Apply a silicone liquid gasket (0000-77-1217-ES Mazda required sealant) to the thread of
the end cap and tighten it. This tube will repair at least 25 vehicles. PLEASE CLICK HERE TO
WATCH THE VIDEO OF THE PROCEDURE. (Right Hand drive vehicle is shown. but repair
is the same) NOTE: THE SEALANT IS GRAY IN COLOR FROM PN# 0000-77-1217-ES)
Tightening torque: 9-12 lbf-ft (12-16 N-m)
BEFORE TORQUE WITH GREASE AFTER TORQUE
Page 15 of 17
20. PHOTO REQUIREMENT #4. Take a photo for a warranty claim.
Take a photo so that the black cover and end cap are visible.
REPAIR PROCEDURE
SAFETY RECALL 6524A
NOTE: THE RO ON THE CASE MUST MATCH THE RO IN THE PHOTO, THIS
WILL BE CHECKED. NOTE: Paperless dealers: RO in 4th photo is NOT
Required to save printing costs, but write the RO on the steering gear.
NOTE: Paperless dealers: RO
in 4th photo is NOT Required,
to save printing costs but write
the RO# on the steering gear.
21. Reinstall the #3 Under Cover. Refer to MGSS online {FRONT UNDER COVER# 3 REMOVAL/
INSTALLATION)
Page 16 of 17
y
2 1 2
r.]
azzdjw00000584
Step Part name
1 Bolt
2 Fastener
3 Front undercover No.3
22. Steering operation check:
Applicable
condition
All models
All models
All models
REPAIR PROCEDURE
SAFETY RECALL 6524A
Tightening torque
11 N-m {110 kgf-cm, 95 in-lbf}
–
–
a. Lower the vehicle to approximately 1 ft from the ground, on the lift
b. Push the start button to the IG-ON position (engine does not start/ PHEV is not
Page 17 of 17
➢
➢
Ready- ON)
REPAIR PROCEDURE
SAFETY RECALL 6524A
c. Make one full steering wheel revolution, from full left to full right, lock-to-lock
d. Follow the flow chart to make sure that there is no binding in the steering wheel
From lock-to-lock, is the steering wheel
binding or heavy?
Move to step 23.
Go back to step 13-16 and check
the spring is replaced. Make sure
the cap is in place and the new
spring is installed, with grease.
If the steering is binding or heavy when turning the steering wheel:
– Check if the removed spring is outside half white.
– Check if the pushing grease procedure has been done properly.
If steering wheel is heavy to turn :
Verify that there the spring seat is removed. Steering wheel becomes heavy if the old
spring seat remains in the housing.
23 . Place the vehicle on the ground, and open the hood. Move to Section C. Campaign
Label Replacement.
C. CAMPAIGN LABEL INSTALLATION
a. Fill out a Black “Campaign Label” (9999-95-0SSA-06) with Campaign#: “6524A”,
your dealer code, and the repair date.
CAMP IGN LABEL
CAMPAIGI NO: __ _
DEALER COOE: __ _
DATE / /
b. Affix it to the hood as shown. If you cannot place the label here, the radiator
support, firewall or driver door jamb are acceptable locations:
END OF REPAIR PROCEDURE
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MAZDA D • ALER • MAIL
January 30, 2024
Attention: Mazda General, Parts and Service Managers
Subject: REPAIRPROCEDUREUPDATE-PHOTO REQUIREMENT-SafetyRecall 6524A-2024MY
CX-90- Sudden Increase in Steering Effort
Dear Mazda Dealer Partners,
ACTION REQUIRED, REPAIR PROCEDURE UPDATE:
We appreciate the feedback on our requirements for this repair and recognize that the request for
multiple photos was a challenge. Based on this feedback, our continued partnership and the joint
desire to ensure all recalls are completed correctly, MNAO Warranty and Recall Operations are
pleased to announce changes to the repair procedure supporting this recall.
The repair procedure was simplified today, reducing the previous requirement of four (4) photos to
only one (1) specific photo that is required to be taken and attached to the warranty claim. Any
repairs or claims in process or not submitted, regardless of the date will only require this photo
to be attached.
Please ensure your technicians pull up the latest repair procedure to identify the required photo
and ensure the photo shows the items called out in the photo clearly. Please read all steps in the
document as there are other minor changes and warnings. The repair order is not required to be in
frame on the photo. The technician only has to write the RO# on the steering rack for
identification which is matched to the claim.
The Parts and Warranty information was modified to require only one D40 Photo requirement. If
you have any questions regarding this change please fill out the Dealer Recall Help Form located on
OneMazda. The repair time remains the same.
Please make certain the appropriate personnel in your dealership are aware of this
change and additional resources for 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 are greatly appreciated.
Sincerely,
Mazda North American Operations
Travis Young
Manager, Recalls Technical Services Division
M;\Z DA NORTH i\,”1E RICAN OPE RAT 10,
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