NHTSA Complaint #10593771 — 2004 MAZDA RX-8

ON 2/9/12 MY 2004 MAZDA RX-8 WAS BROUGHT IN FOR ENGINE REPLACEMENT AS PART OF A RECALL. SINCE THE ENGINE REPLACEMENT THE CLUTCH IS ENGAGING AT DIFFERENT PLACES OR STICKING TO THE FLOOR. ON 3/30/12 THE CAR WAS TAKEN BACK TO DICK EDWARDS MANHATTAN FOR "...WHEN CLUTCH IS ENGAGED THERE IS A FUNNY NOISE COMING FROM TRANSMISSION & THERE IS A VIBRATION." IT WAS MISDIAGNOSED AND NOT FIXED. THE CAR WAS TAKEN BACK TO THE DEALERSHIP ON 6/26/12 BECAUSE "WHEN USING CLUTCH THAT THE FIRST HALF OF THE PEDAL IS EMPTY AND THE SECOND HALF ENGAGES BUT IF YOU TRY TO SHIFT IN THE MIDDLE IT WILL GET STUCK AND NOT COME OUT." IT WAS MISDIAGNOSED & NOT FIXED. ON 10/26/12 IT WAS TAKEN TO OVERLAND PARK MAZDA & IT WAS FOUND THAT "CLUTCH WAS STICKING TO THE GROUND AND TRACED TO THE MASTER AND SLAVE CYLINDER..." IT WAS MISDIAGNOSED & NOT FIXED. ON 11/9/12 THE CAR WAS BROUGHT TO OVERLAND PARK MAZDA TO "BLEED CLUTCH AND ADJUST FREE PLAY FROM CLUTCH PEDAL PUSH ROD TO MAKE CLUTCH PEDAL MORE RESPONSIVE." THE PROBLEM WAS STILL NOT FIXED. IN 8/13 I BOUGHT THE CAR IN KANSAS CITY, MO. SINCE THEN I HAD THE CLUTCH DIAGNOSED AT RICK'S PERFORMANCE IN CALIFORNIA WHO FOUND "PLAY IN THE ENGINE CRANKSHAFT - THE FLYWHEEL IS MOVING BACK AND FORTH OVER 1/2 INCH" & CONCLUDED THAT THE ENGINE REPLACED IN THE RECALL ON 2/9/12 AT DICK EDWARDS MANHATTAN WAS DEFECTIVE AND THAT A PART HAD BEEN LEFT OUT OF THE ENGINE DURING ASSEMBLY. I TOOK THE CAR TO KEN HARVEY'S DUBLIN MAZDA IN DUBLIN, CA AND THEY CONFIRMED THE DIAGNOSIS BY RICK'S PERFORMANCE & RECOMMENDED MAZDA REPLACE THE ENGINE AS IT SHOWS SIGNS OF INTERNAL DAMAGE. HOWEVER, MAZDA REFUSED TO REPLACE THE ENGINE AS IT IS OUTSIDE OF THE 1 YEAR/12,000 MILE WARRANTY EVEN THOUGH IT HAD BEEN BROUGHT IN FOR SERVICE 4 TIMES WITHIN THE WARRANTY BUT WAS NEVER FIXED. ALSO, ONLY 9K MILES HAVE BEEN PUT ON THE CAR IN THAT TIME FRAME. *TR