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SUMMARY:
Mazda North American Operations (Mazda) is recalling certain model year 2004-2006 B-Series trucks manufactured April 17, 2003, to May 2, 2006.
Upon deployment of the driver side frontal air bag, excessive internal pressure may cause the inflator to rupture.
CONSEQUENCE:
In the event of a crash necessitating deployment of the driver’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 driver side frontal air bag inflators, free of charge.
The recall is expected to begin March 25, 2016.
Owners may contact Mazda customer service at 1-800-222-5500.
Mazda’s number for this recall is 9116A.
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: March 2016
SUBJECT: 2004-2006 B-Series Truck Driver Frontal Air Bag Inflator INTERIM REPAIR Safety Recall 9116A
Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists in all 2004-2006 B-Series trucks. In the subject vehicles, continued exposure to high levels of absolute humidity may cause the driver frontal air bag inflator housing to rupture and deploy abnormally in the event of a crash necessitating deployment of the driver frontal air bag. An inflator rupture could result in metal fragments striking the driver or other vehicle occupants, resulting in serious injury or death.
Dealers are to replace the driver 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 in Attachment IV. Until permanent remedy parts are available, please continue to install current replacement parts for recall 9116A. Please inform customers that, although the original design has not changed, current replacement inflators are safer to use as an interim fix because they have not been exposed to high absolute humidity, which is believed to be the cause of the abnormal deployment issue. When the new, modified inflators become available, a new recall will be launched and affected owners will be notified to return to their Mazda dealer for permanent remedy parts.
Owner Notification
Owners of affected vehicles will be notified by first class mail beginning March 28, 2016.
Parts Information
| Description | Part Number | Quantity | Model |
| Driver Frontal Air Bag Inflator | 1FTT-57-K00 | 1 | B-series truck |
Since parts are needed on a VIN level basis and should not become a stocked item in your dealership, the parts for this recall are non-returnable.
This package contains important information about Recall Campaign 9116A:
| Attachment I | Dealer Service Information |
| Attachment II | Repair Procedure |
| Attachment III | Owner Notification Letter |
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:
- The attached service information (Attachment I) and repair procedure (Attachment II) are available on eMDCS and MS3 (Mazda Service Support System) websites via MXConnect.
- For technical assistance, contact the Technical Assistance Hotline at (888) 832-8477, Option 3.
- For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
- For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626 Option 2.
- 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.
ATTACHMENT I
SERVICE INFORMATION
Safety Recall 9116A
CONDITION OF CONCERN
In the subject vehicles, continued exposure to high levels of absolute humidity may cause the driver frontal air bag inflator housing to rupture and deploy abnormally in the event of a crash necessitating deployment of the driver frontal air bag. An inflator rupture could result in metal fragments striking the driver or other vehicle occupants, resulting in serious injury or death.
Dealers are to replace the driver 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 in Attachment IV. Until permanent remedy parts are available, please continue to install current replacement parts for recall 9116A. Please inform customers that, although the original design has not changed, current replacement inflators are safer to use as an interim fix because they have not been exposed to high absolute humidity, which is believed to be the cause of the abnormal deployment issue. When the new, modified inflators become available, a new recall will be launched and affected owners will be notified to return to their Mazda dealer for permanent remedy parts.
These are the same vehicles subject to Safety Recall 8315F.
SUBJECT VEHICLES
| Model | VIN range | Build Date Range |
| 2004-2006 B-Series Truck | All | April 17, 2003 through May 2, 2006 |
Note: The asterisk symbol “*” can be any letter or number.
MANDATORY AIR BAG INFLATOR RETURN
The original air bag inflator(s) should be returned by your dealership every 30 days or once 200 inflators have been accumulated. All inflator part numbers can be counted and shipped together for these returns. To schedule a return, please contact XPO at (877) 6503476. Detailed air bag inflator return instructions are provided in Attachment IV, and can also be found on MS3 and the Dealer Assistance Group website. Failure to return the original inflator will result in a Warranty Claim Debit.
OWNER NOTIFICATION
Mazda will notify U.S. owners by first class mail beginning March 28, 2016.
PARTS INFORMATION
A web page to order parts for this recall is available in MXConnect. A complete VIN is needed to process the order. Replacement parts for this recall are non-returnable.
| Description | Part Number | Quantity | Notes |
| Driver Frontal Air Bag Inflator | 1FTT-57-K00 | 1 | |
| Campaign Label | 9999-95-065A-06 | 1=50 labels | Obtain in Mazda e-Store (no charge) |
WARRANTY CLAIM PROCESSING INFORMATION
| Repair | Replacement of Driver Frontal Air Bag Inflator |
| Applicable Model | B-series |
| Warranty Type | R |
| Process Number | J1601A |
| Symptom Code | 99 |
| Damage Code | 99 |
| Part Number Main Cause & Quantity | 1FTT-57-K00 / 1 qty |
| Labor Operation Number | YY778XRX |
| Labor Hours | 0.6 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 | 5555-91-16AR | 5555-91-16AL |
| 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 |
Rental expenses exceeding the two-day limit will require prior DSM Authorization, as outlined in the Mazda Rental Car Reimbursement Program policy.
VERIFY THE VEHICLE NEEDS THE RECALL
- Verify the vehicle is within the following ranges:
| Model | VIN range | Build Date Range |
| 2004-2006 B-Series Truck | All | April 17, 2003 through May 2, 2006 |
Note: 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, Recall 9116A is not applicable.
- Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for an Authorized Campaign Label RECALL 9116A attached to the vehicle’s hood or bulkhead.
eMDCS System – Warranty Vehicle Inquiry Results:
| If eMDCS displays: | Campaign Label is: | Action to perform: |
| RECALL 9116A | Present | Contact the Warranty Hotline at (877) 727- 6626, option 3, to update vehicle history. |
| Not present | Proceed to “REPAIR PROCEDURE”. | |
| RECALL 9116A CLOSED | Present | Return vehicle to inventory or customer. |
| Not present | Complete a label and apply to vehicle’s hood or bulkhead. | |
| RECALL 9116A is not displayed | Does not apply | Recall does not apply to this vehicle. Return vehicle to inventory or customer. |
REPAIR PROCEDURE
Please refer to Attachment II.
ATTACHMENT II
2004-2006 B-SERIES – DRIVER AIR BAG SAFETY RECALL 9116A
A. VEHICLE INSPECTION PROCEDURE
- Verify that the vehicle is within the following ranges:
| Model | VIN 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.
- Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Labels Recall 9116A 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 9116A OPEN | Present | Contact the Warranty Hotline at (877) 727-6626 option 3 to update vehicle history. |
| Not present | Proceed to “B. REPAIR PROCEDURE”. | |
| RECALL 9116A CLOSED | Present | Return vehicle to inventory or customer. |
| Not present | Proceed to “C. CAMPAIGN LABEL INSTALLATION”. | |
| RECALL 9116A is not displayed | Does not apply | Recall does not apply to this vehicle. Return vehicle to inventory or customer. |
B. REPAIR PROCEDURE
Outline:
Remove the airbag from the vehicle and replace only the inflator portion of the airbag. The original (old) inflator will be placed into the packaging from the new inflator and shipped to Takata using the included return shipping label.
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 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.
- Turn the ignition switch to the LOCK position.
- Record the customer’s preset radio stations.
- Disconnect the negative battery cable and wait for one (1) minute or more.
- Remove the driver air bag module. Refer to DRIVER AIR BAG MODULE REMOVAL / INSTALLATION on MS3 online or in the Workshop Manual (section 08-10).
- Lay a protective cloth on the work bench, then place the air bag module on it to avoid any damage or scratches to the surface.
WARNING: Do not allow any debris on or around air bag once the inflator is removed.
Inflator Replacement:
- Release the retaining tab and slide the connector (A) of the air bag inflator (B) off the tang.
- Remove and discard the four air bag inflator retaining nuts (C)
- Remove the air bag inflator and set aside for return shipping.
NOTE: In order to verify the correct airbag inflator is installed, mark the old airbag inflator with a felt tip marker prior to removal.
- Install the new inflator into the driver air bag.
NOTE: The new air bag inflator must be installed in the same orientation as the original part to ensure the inflator module and air bag harness electrical connector T-shape indexes (A) are aligned properly.
- Install and connect the new air bag wiring harness to the inflator module.
- Install four new air bag inflator nuts onto the driver airbag (C). Tightening torque: 6.5 Nm (57 lb-in)
- Slide the connector (A) of air bag inflator (B) onto the tang.
Air Bag Module Reinstallation:
- Install the driver air bag module. Refer to DRIVER AIR BAG MODULE REMOVAL / INSTALLATION on MS3 online or in the Workshop Manual (section 08-10).
- Reconnect the negative battery cable.
- Turn the ignition switch to the ON position.
- 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).
- Re-enter the customer’s preset radio stations.
- Proceed to “C. CAMPAIGN LABEL INSTALLATION”.
C. CAMPAIGN LABEL INSTALLATION
- Fill out a blue “Campaign Label” (9999-95-065A-06) with Campaign No: “9116A”, your dealer code, today’s date.
- Affix it to the hood or bulkhead as shown:
- Return the vehicle to customer.
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IMPORTANT SAFETY RECALL
2004-2006 B-Series Truck
Safety Recall 9116A – Driver Air Bag Inflator Replacement
March 2016
This notice applies to your vehicle: VIN _________________
Dear Mazda Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists in 2004-2006 B-Series Trucks.
If you are a recipient of this notice, your vehicle is included in this recall.
What is the problem?
In the subject vehicles, continued exposure to high levels of absolute humidity may cause the driver’s front air bag inflator housing to rupture and deploy abnormally in the event of a crash necessitating deployment of the driver’s frontal air bag. An inflator rupture could result in metal fragments striking the driver or other vehicle occupants, resulting in serious injury or death.
What will Mazda do?
Replacement parts for this recall are not yet available. When replacement parts are available, we will notify you again by mail, asking you to contact any authorized Mazda dealer to schedule a service appointment to have the driver air bag inflator replaced, free of charge.
What should you do?
Please wait until you receive another notification from Mazda by mail, informing you that the replacement parts for this recall repair are available.
Where is the closest Mazda dealer?
To locate your nearest Mazda dealer, visit our web site and use our “Locate a Dealer” feature at www.MazdaUSA.com or consult your local yellow pages.
Moved or no longer own this vehicle?
If you have moved or no longer own your Mazda vehicle, please complete the enclosed prepaid Information Change Card as soon as possible. This enables us to update our records and notify the current owner.
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Still have questions?
If you have any questions regarding this campaign, please contact our Customer Experience Center at (800) 222-5500, option #6.
If Mazda or its dealers do not repair the defect free of charge and within a reasonable amount of time, you may notify the Administrator of the National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327 4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov.
We actively work to improve our products and search for solutions to improve your ownership experience. We sincerely apologize for any inconvenience this recall may cause you.
Sincerely,
Mazda North American Operations
IMPORTANT SAFETY RECALL
2004-2006 B-Series Truck
Safety Recall 9116A – Driver Air Bag Inflator Replacement
March 2016
This notice applies to your vehicle: VIN _________________
Dear Mazda Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists in 2004-2006 B-Series Trucks.
If you are a recipient of this notice, your vehicle is included in this recall.
You may have been previously notified of passenger air bag inflator replacement under Safety Recall 8315F. If the passenger air bag inflator has not yet been replaced on your vehicle, please be sure to have both air bag inflators replaced at an authorized Mazda dealer.
What is the problem?
In the subject vehicles, continued exposure to high levels of absolute humidity may cause the driver’s front air bag inflator housing to rupture and deploy abnormally in the event of a crash necessitating deployment of the driver’s frontal air bag. An inflator rupture could result in metal fragments striking the driver or other vehicle occupants, resulting in serious injury or death.
What will Mazda do?
Your Mazda dealer will replace the driver’s frontal air bag inflator with a new one, free of charge. The repair should take less than an hour to complete; however, it may take longer depending on the service workload at your Mazda dealership.
If necessary, Mazda will provide alternate transportation while your vehicle is at an authorized Mazda dealership for this repair.
What should you do?
We encourage you to contact any authorized Mazda dealer to schedule an appointment to have your vehicle repaired as soon as possible. You do not need to bring this notice to the dealer, but it may assist in the check-in process.
Where is the closest Mazda dealer?
To locate your nearest Mazda dealer, visit our web site and use our “Locate a Dealer” feature at www.MazdaUSA.com or consult your local yellow pages.
Moved or no longer own this vehicle?
If you have moved or no longer own your Mazda vehicle, please complete the enclosed prepaid Information Change Card as soon as possible. This enables us to update our records and notify the current owner.
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Still have questions?
If you have any questions regarding this campaign, please contact our Customer Experience Center at (800) 222-5500, option #6.
If Mazda or its dealers do not repair the defect free of charge and within a reasonable amount of time, you may notify the Administrator of the National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327 4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov.
We actively work to improve our products and search for solutions to improve your ownership experience. We sincerely apologize for any inconvenience this recall may cause you.
Sincerely,
Mazda North American Operations
