8315F – Passenger Air Bag Inflator Replacement – 2004-2006 Mazda B-Series Trucks

NHTSA

15V346

SUMMARY:

Mazda North American Operations (Mazda) is recalling certain model year 2004-2006 Mazda B-series light trucks manufactured from April 17, 2003, through May 2, 2006.

The affected vehicles are equipped with a passenger side frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture upon deployment.

CONSEQUENCE:

In the event of a crash necessitating deployment of the passenger’s frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants, potentially resulting in serious injury or death.

REMEDY:

Mazda will notify owners, and dealers will replace the the passenger side frontal air bag inflator, free of charge.

The recall began on July 28, 2015.

Owners may contact Mazda at 1-800-222-5500.

Mazda’s number for this recall is 8315F.

Note: This recall expands and partially supersedes recall 14V773 as to the model year 2004 through 2006 Mazda B-series vehicles only.

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

 

TO: All Mazda Dealership General Managers, Service Managers, and Parts Managers

DATE: July 2015

SUBJECT: Passenger Air Bag Inflator Replacement – Safety Recall 8315F

Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists in all 2004-2006 B-Series trucks.

For the subject vehicles, this recall replaces 8114L.

In the subject vehicles, continued exposure to high levels of absolute humidity may cause the passenger frontal air bag inflator housing to rupture and deploy abnormally in the event of a crash necessitating deployment of the passenger frontal air bag. An inflator rupture could result in metal fragments striking and potentially seriously injuring vehicle occupants.

 

Dealers are to replace the passenger air bag inflators of subject vehicles with a new one. The original inflator must be returned to the manufacturer for analysis according to the instructions described in Attachment IV.

OWNER NOTIFICATION

Owners of subject vehicles will be notified by first class mail beginning July 27, 2015.

PARTS INFORMATION

A web page to order parts for this recall is available in MXConnect.  A complete VIN is needed to process the order.

Description	Part Number	Quantity	Notes
Passenger Side Front  Air Bag Inflator	1FTT-57-K50	1	B-series truck

 

This package contains important information about Safety Recall 8315F:

Attachment  I	Dealer Service and Parts Information
Attachment II	Repair procedure
Attachment III	Owner notification letter
Attachment IV	Air Bag Inflator Return Instructions

 

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. The attached service information, repair procedure, parts information, and air bag inflator return instructions are available on eM DCS and MS3 (Mazda Service Support System) websites via MXConnect.
2. For technical assistance, contact the Technical Assistance Hotline at (888) 832-8477, Option 3.
3. For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626, Option 2.
4. For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
5. We recommend using the Recall Reminder Report #JS30R165-1 and Recall Reminder Labels available in Web Reporting to encourage customers to come in for the recall (with recall reminder postcards). Dealers may use such owner information for the sole purpose of conducting and performing this recall, and for no other purpose. Using it for marketing activities is strictly prohibited and could subject your dealership to serious fines. The information in the report is       protected by state privacy and other applicable laws regarding disclosure of personal and/or confidential, restricted or blocked information. It is the dealer’s responsibility to protect the confidentiality of owner records and prevent the release of information to other parties.

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.

Sincerely,

Satoshi Takahashi

Director, Technical Services Division

Mazda North American Operations

 

ATTACHMENT I –SERVICE INFORMATION

Safety Recall 8315F

CONDITION OF CONCERN

In certain vehicles with continued exposure to high levels of humidity over long periods, the front passenger air bag inflator could produce excessive internal pressure in the event of a crash where the front air bag is designed to deploy. The excessive internal pressure may cause the inflator housing to rupture with metal fragments, which may increase the risk of injury to the vehicle occupants. Dealers are to replace the passenger side front air bag inflator of subject vehicles with a new one.

A web page to order parts for this recall is available in MXConnect. A complete VIN is needed to process the order. For each VIN order request, the appropriate part(s) will be automatically selected and ordered based on the VIN.

MANDATORY AIR BAG INFLATOR RETURN

Upon receiving the replacement air bag inflator, the original air bag inflator should be returned the same day the repair is performed. Do not wait for Warranty Claim Entry or Warranty Parts Requests. Failure to return the original inflator will result in a Warranty Claim Debit.

Detailed air bag inflator return instructions are provided in Attachment IV and can also be found on MS3 and the Dealer Assistance Group website.

SUBJECT VEHICLES

Model	VIN Range
2004-2006 B-Series	All

 

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

 

OWNER NOTIFICATION

Mazda will notify U.S. owners by first class mail beginning July 27, 2015.

 

PARTS INFORMATION

Description	Part Number	Quantity	Notes
Passenger Side Front Air Bag Inflator	1FTT-57-K50	1	B-Series Truck
Campaign Label	9999-95-065A-06	1=50 labels	Obtain in MStore (no charge)

 

PARTS ORDERING

A web page to order parts for this recall is available in MXConnect.  A complete VIN is needed to process the order.

WARRANTY CLAIM PROCESSING INFORMATION

Repair	Replacement of Passenger Side  Front Air Bag Inflator
Applicable Model	B-series
Warranty Type	R
Process Number	J1503A
Symptom Code	99
Damage Code	99
Part Number Main Cause & Quantity	5555-15-003A & 0
Related Part Number & Quantity	1FTT-57-K50 & 1
Labor Operation Number	YY775XRX
Labor Hours	0.8 hrs.

 

RENTAL CAR INFORMATION

Mazda will authorize rental and service loaner vehicles on a limited basis. We are requesting dealer understanding and partnership regarding rental and loaner vehicle utilization. Please make every effort to utilize alternative transportation solutions in place of rental use. Rental is covered if customer has no alternative means of transportation.

Rental Car Warranty Claim Information

Please submit rentals on a separate claim problem number as follows:

	Rental Agency Vehicle	Dealer Loaner Car Fleet Vehicle
Warranty Type Code	A	A
Symptom Code	99	99
Damage Code	99	99
Part Number Main Cause	5555-83-15FR	5555-83-15FL
Part Quantity	0	Number of days loaner car was used Mazda pays $35.00/day
Labor Operation Code	MM024XRX	MM024XRX
Labor Hours	0.0	0.0
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 had rental car
Sublet Text	Number of days rental car was supplied to customer

 

VERIFY THE VEHICLE NEEDS THE RECALL

1. Verify the vehicle is within the following ranges:

Model	Build Date Range
2004-2006 B-Series	All

 

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

• If the vehicle is within the above ranges, go to Step 2.
• If the vehicle is not within the above ranges, Recall 8315F is not applicable.

2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect the vehicle for an Authorized Campaign Label RECALL 8315F attached to the vehicle’s hood or bulkhead.

 

  eMDCS System – Warranty Vehicle Inquiry Results:

If eMDCS displays:	Campaign Label is:	Action to perform:
RECALL 8315F OPEN	Present	Contact the Warranty Hotline at (877) 7276626, option 3, to update vehicle history.
	Not present	Proceed to “REPAIR PROCEDURE”.
RECALL 8315F CLOSED	Present	Return vehicle to inventory or customer.
	Not present	Complete a label and apply to vehicle’s hood or bulkhead.
RECALL 8315F is not displayed	Does not apply	Recall does not apply to this vehicle. Return vehicle to customer.

 

REPAIR PROCEDURE

Please refer to Attachment II.
 

ATTACHMENT II

2004-06 B-SERIES TRUCK – PASSENGER AIR BAG SAFETY RECALL 8315F/RECALL TEMPLATE

A. VEHICLE INSPECTION PROCEDURE

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

Model	VIN Range	Build Date Range
2004-2006 B-Series	All	—

 

• 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 Recall 8315F 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 8315F OPEN	Present	Contact the Warranty Hotline at (877) 727-6626 option 3 to update vehicle history.
	Not present	Proceed to “B. REPAIR PROCEDURE”.
RECALL 8315F CLOSED	Present	Return vehicle to inventory or customer.
	Not present	Proceed to “C. CAMPAIGN LABEL INSTALLATION”.
RECALL 8315F is not displayed	Does not apply	Recall does not apply to this vehicle. Return vehicle to inventory or customer.

 

B. REPAIR PROCEDURE

Passenger-Side Air Bag Inflator Replacement Procedure:

Parts Information: The service parts are available in one box.

Outline:

1. Remove the inflator from the passenger-side air bag module (A), then replace it with a modified one (B).

2. Pack and return the removed inflator as follows:

IMPORTANT: Be sure to follow the packing and shipping instructions provided in the carton and in Attachment IV, Air Bag Inflator Return Instructions.

CAUTION:

• Use the same carton which was used to deliver a new inflator. It is a specialized box that is internationally accepted for shipping an inflator.
• Pack the old inflator in the box exactly in the same manner as the new inflator was packed.

 

Air Bag Module Removal:

WARNING:

• Perform the replacement in a clean environment. Oil, grease, water, etc. on components may cause the air bag modules to fail to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., on components.
• Inserting a screwdriver, etc., into the connector of an air bag module may damage the connector and cause the air bag module to deploy improperly, which may cause serious injury. Do not insert any foreign objects into the connector.
• Do not disassemble the vehicle, other than instructed here.
• Do not make an attempt to directly supply electrical power to the module and the inflator.
• Keep the module facing of the pad surface upwards at all times, except during replacement.
• Do not use the module and new inflator if they were dropped on the ground.
• Avoid module and inflator exposure to temperatures of 194 degrees F (90 degrees C) or more.

1. Turn the ignition switch to the LOCK position.
2. Record the customer’s preset radio stations.
3. Disconnect the negative battery cable and wait for one (1) minute or more.
4. Open the glove compartment door to access the passenger air bag electrical connector.

5. Release the tab and disconnect the passenger air bag module electrical connector

6. Remove the two passenger air bag module bolts (A).

7. Remove the passenger airbag. If necessary, push down on the top and up on the bottom of the deployment door while pushing out on the passenger air bag module, releasing the clips from the instrument panel and remove the passenger air bag module

CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment doors. Place one hand in the glove compartment and push the passenger air bag out.

 

Inflator Replacement:

1. Set the airbag face down onto a surface that will not scratch or damage the airbag face.
2. Remove the wiring harness connector retaining clip (A) from the wiring harness connector. (B)

3. Remove the two airbag inflator retaining bracket nuts (A) and the airbag inflator retaining bracket (B). Discard the nuts.

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

With an assistant holding the airbag assembly, remove the inflator (A) from the airbag assembly by pushing outward on the inflator. Set the airbag inflator aside for return shipping.
IMPORTANT:

• If required, use of a brass punch (B) is permitted only at the location shown to free the inflator from its mounted position.
• Return the removed inflator in the same carton in which the new part was received. Carefully follow the packing and shipping instructions included in the carton.

5. Install the new passenger side airbag inflator into the airbag assembly.

NOTE: The indexed end of the airbag inflator must be installed first (A) to mate with the permanently mounted bracket.

6. Install the passenger side air bag inflator retaining bracket (B) and install the two nuts (A).

Tightening Torque: 35 +/- 1.8 in-lbf. {39.8 +/- 2.0 kgf-cm, 3.9 +/- 0.4 Nm}

7. Connect the new wiring harness (A) to the passenger air bag inflator.

 

Air Bag Module Reinstallation:

1. Install the air bag module assembly. Angle the top of the passenger air bag module into the instrument panel first so that the deployment door upper clips engage to the instrument panel. Push up and in at the top and down and in at the bottom of the deployment door to seat all the clips to the instrument panel.

CAUTION:    DO NOT handle the passenger air bag module by grabbing the edges of the deployment doors. Position the passenger air bag module into the instrument panel.

2. Align the passenger air bag module and install the bolts (A).

Tightening Torque: 80 in-lbf. {9 Nm}

3. Connect the passenger air bag module electrical connector.

4. Close the glove compartment door.
5. Reconnect the negative battery cable.
6. Turn the ignition switch to the ON position.
7. Verify that the air bag system warning light illuminates for approx. 6 sec., then goes out.

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 MS3 online or the Workshop Manual (section 08 Restraints).

8. Re-enter the customer’s preset radio stations.
9. Proceed to “C. CAMPAIGN LABEL INSTALLATION”.

 

CAMPAIGN LABEL INSTALLATION

1. Fill out a blue “Campaign Label” (9999-95-065A-06) with Campaign No: “8315F”, your dealer code, today’s date.

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

3. Return the vehicle to customer.