NHTSA Complaint #10662596 — 2006 MAZDA MAZDASPEED6

5 MONTHS AGO, TOOK CAR TO MAZDA DEALER FOR TIMING CHAIN, VVT NOISE AND WAS REPLACED UNDER EXTENDED WARRANTY. LAST MONTH STARTED TO FEEL INTERMITTENT LOSS OF POWER DURING QUICK ACCELERATION FOLLOWED BY PLUME OF SMOKE AT THE TAIL PIPE. TOOK TO LOCAL MECHANIC SHOP AND WAS TOLD THERE WAS HEAVY CARBON BUILDUP AT THE VALVES AS WELL AS MASS AIR FLOW SENSOR, O2 SENSOR, AND OTHER ENGINE COMPONENTS. THE BILL WAS FOR ABOUT 1800 WORTH OF PARTS AND LABOR FOR DEEP CLEANING THE VALVES (INTAKE MANIFOLD REMOVED). AFTER REPAIRS WERE COMPLETED, TOOK CAR HOME AND DROVE FOR ABOUT 25 MILES WHEN I HEARD A LOUD BANG FROM THE ENGINE COMPARTMENT. THE ENGINE SUDDENLY STOPPED AND I SMELLED BURNT OIL AND SMOKE INSIDE THE CABIN. I WAS ABLE TO STEER THE CAR TO THE SIDE AND LOOKED UNDER THE CAR TO FIND LARGE AMOUNTS OF OIL LEAKING FROM ENGINE. HAD THE CAR TOWED TO SAME MECHANIC AND WAS TOLD A ROD SHEARED AND BLEW A HOLE THROUGH THE BLOCK AND PUNCTURED THROUGH THE TRANSFER CASE HOUSING. THERE WAS NO ROD BEARING FAILURE, THE ROD JUST SNAPPED IN HALF. THE EXTENDED WARRANTY WILL NOT COVER THE ENTIRE REPAIR COST AND WILL NOT COVER THE TRANSFER CASE DAMAGE. READING THROUGH SEVERAL FORUMS, THE SAME ENGINE DAMAGE HAS OCCURRED TO SEVERAL OTHER MAZDASPEED 6 OWNERS. THIS TYPE OF ENGINE FAILURE APPEARS TO BE A MANUFACTURING DEFECT. AN INVESTIGATION SHOULD BE CONDUCTED TO DETERMINE THE ROOT CAUSE OF THESE CATASTROPHIC ENGINE FAILURES. *TR