2012 Mazda CX-9

The defect

Mazda North American Operations (Mazda) is recalling certain model year 2007-2014 CX-9 vehicles manufactured October 24, 2006, to December 28, 2013. The affected vehicles have front suspension ball joints that may corrode from water leaking into the fitting.

The risk

Over time, the ball joint corrosion may result in the front lower control arm separating from the ball joint, causing a loss of steering control and increasing the risk of a crash.

The remedy

Mazda will notify owners, and dealers will replace both the left and right lower control arms, free of charge. The recall began on September 14, 2015. The recall will begin with model year 2007-2009 vehicles registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, Washington D.C., West Virginia, and Wisconsin. The second phase will be for model year 2010-2014 vehicles in the same states. Finally, all remaining vehicles will be remedied. Owners may contact Mazda customer service at 1-800-222-5500. Mazda's number for this recall is 8515G.

Mazda North American Operations · up to 193,484 vehicles across all model years covered

Closed preliminary evaluation · opened May 2, 2019 · closed January 15, 2021

the air bags

The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE19-006) on May 2, 2019 to investigate two Vehicle Owner Questionnaires (VOQs) and Early Warning Reporting data related to allegations of inadvertent deployment (IAD) of side curtain airbags in Model Year (MY) 2010 through 2013 Mazda CX-9 vehicles. ODI sent an Information Request (IR) to Mazda North America Operations, LLC. to gather information about the alleged defect in the subject vehicles. In the 20 months since opening the PE, ODI has received three additional VOQs. To date, there have been a total of 11 IAD incidents within the identified population of 104,360 vehicles. Of the 11 incidents, no serious injuries were reported. The last known incident occurred in December 2020.Mazda's response to ODI's IR letter identified the root cause as a manufacturing issue of the Bosch SMG076 Roll Rate Sensor within the Restraint Control Module (RCM). During the manufacturing calibration process, small particles may be generated that could affect roll sensor capacitance, which could lead to a loss of curtain airbag protection or an erroneous deployment command. On November 19, 2012, a revised Roll Rate Sensor calibration process was launched, establishing a clean point for the issue. In its responses to ODI, Mazda has assessed the condition as a low risk to motor vehicle safety, with low incident frequency not warranting action. Any RCM data indicating a malfunctioning Roll Rate Sensor will result in the illumination of the airbag warning light. In the event of an erroneous curtain airbag deployment, there is no contact with properly seated occupants. Additionally, the condition is not affected by deterioration or wear, and known incidents established a random pattern of occurrence.During the investigation, ODI examined the injury risk to vehicle occupants from curtain airbag deployments. It was determined that the subject vehicles do not pose a substantial risk to out of position occupants, as testing data falls within Technical Working Group (TWG) reference values. Modeling simulation based on data provided by Mazda for properly seated occupants during static and dynamic airbag deployments indicated sufficient head clearance and no risk of brain injury. ODI analysis reveals that inadvertent deployment incident rates of curtain airbags in the subject vehicles are low through approximately ten years in service. Incident frequency does not meet values warranting recall action, but rather align closely with baseline frequency of general inadvertent deployments which are known to occur in rare driving conditions. Additionally, warranty analysis of RCM failures resulting in a loss of curtain airbag protection revealed low claim rates.Based on the analysis conducted, this investigation has been closed. The closing of this investigation does not foreclose the Agency from taking further action, if warranted, or the potential for a future finding that a safety-related defect exists, based upon additional information the Agency may receive.The five ODI complaints cited above can be reviewed at NHTSA.gov under the following identification numbers: 10905492, 11165925, 11270089, 11310044, 11385219.

Closed preliminary evaluation · opened June 9, 2015 · closed August 20, 2015 · led to recall 15V451000

the suspension

In an July 7,2015 letter to NHTSA, Mazda identified a safety defect that could result in lower ball joint separation in approximately 193,484 model year (MY) 2007 through 2014 Mazda CX-9 vehicles (NHTSA Recall No. 15V-451,Mazda 8515G).Mazda indicated that damage to the ball joint boot may allow water to enter the front suspension ball joint fitting during use which may result in premature ball joint wear and a progressively looser joint.In January 2014, Mazda implemented redesigned lower control arms in production vehicles to improve the durability of the lower ball joints.The redesign involved changing the shape of the top surface of the ball joint boot cover and adding a suspension plate to the undersurface of the knuckle.Mazda's recall will replace the defect lower control arms with the redesigned parts.ODI's analysis of information collected during PE15-022 identified a total of 62 ball joint separation incidents, including 34 identified in ODI complaints and 31 identified in Mazda complaints and field reports (3 of the Mazda records involve vehicles/incidents that were also reported to ODI).When Mazda's design change was implemented, most of the field experience related to lower ball joints involved complaints of noise and premature wear-out.Only 1 of the ODI and 6 of the additional Mazda separation complaints identified in ODI's analysis were reported prior to January 2014.Significant increases in the number and trend in separation complaints were observed in 2015, when 30 of the ODI complaints and 16 of the additional Mazda complaints were reported.The report trend appears to be accelerating, with 29 of the reports received after ODI opened PE15-022 on June 9, 2015.There has been one crash reported to ODI related to the alleged defect (VOQ 10746510). This investigation is closed based on Mazda's recall.The 34 VOQs associated with this investigation are: 10747358, 10746510, 10744897, 10743509, 10736229, 10735938, 10734763, 10734302, 10734290, 10733813, 10732578, 10732217, 10732154, 10731850, 10730736, 10730280, 10730143, 10730114, 10726622, 10726480 10726448, 10726168, 10725839, 10725567, 10725488, 10725427, 10725390, 10717510, 10714469, 10695142, 10668978, 10648429, 10640541, 10546535

While drive i feel like there is sticking something below the car when i am accelerating. And the acceleration became hard. Also i heard a weird noise at that time. Then a saw a leakage below my car.

NHTSA complaint 11665737. Filed by an owner and not verified by NHTSA or by us.

My driver and passenger side curtain airbags randomly deployed without a collision. Thankfully I was at a stop sign when this happened. If it happened while I was driving, I’m sure I would have wrecked and could possibly be dead. It was loud! I thought I’d been shot or that I’d driven over a bomb. We did take the car to someone that’s certified in airbags and it was stated that this was due to a manufacturer’s defect. I also have lots of pictures. There was no warning when the airbags deployed. Mazda is refusing any responsibility due to the car being outside of the warranty.

NHTSA complaint 11640738. Filed by an owner and not verified by NHTSA or by us.

Ball joints replaced due to tear in both rubber covers and driver side ball joint very loose. Was previously repaired in July 2015 under recall Number: 15V451000.

NHTSA complaint 11614843. Filed by an owner and not verified by NHTSA or by us.

I was driving normally when I started sowing down and noticed the brakes were harder to push. I finally stopped just before almost rear-ending a vehicle in front of me. It turns out the brake booster, a known problem that was not communicated to me a few years ago, failed and makes braking the vehicle harder, increases distance, and makes the vehicle unsafe to drive. The problem has been reproduced via a diagnostic test at Mazda of Gladstone dealership on 9/27/23. The dealership has been the only people who have inspected the issue. There were no warning signs, no warning lights, nothing. It was scary because I didn't think my vehicle was going to stop. It's completely dangerous. I have not …

NHTSA complaint 11547325, quoted in part. Filed by an owner and not verified by NHTSA or by us.

The water pump suddenly started leaking and the mechanics I talk to said this is a very common problem with this vehicle and type of engine. Sounds like owners are left to foot the bill for this costly and difficult repair of a defective product. Hopefully more owners come forward and report their experience in this regard

NHTSA complaint 11534076. Filed by an owner and not verified by NHTSA or by us.

crash · 11,000 miles

The contact owns a 2012 Mazda CX9. The contact stated that the vehicle had previously been involved in a crash due to a fractured passenger's side lower control arm. The dealer was made aware of the failure and confirmed that the vehicle had been repaired under NHTSA Campaign Number: 15V451000 (Suspension). The dealer referred the contact to the manufacturer for assistance. An independent mechanic replaced the passenger's side lower control arm; however, the contact stated that after the repair was performed, the engine rattled and the vehicle stalled. The vehicle was then taken back to the independent mechanic, who determined that the driver's side lower control arm spacers were missing …

NHTSA complaint 11532135, quoted in part. Filed by an owner and not verified by NHTSA or by us.