NHTSA Complaint #11100769 — 2012 MAZDA CX-9

AWD TRANSFER CASE UNIT FAILURE THE TRANSFER CASE OF MY 2012 MAZDA CX-9 FAILED WHILE DRIVING ON THE HIGHWAY AT CRUSISING SPEED CREATING A DANGEROUS SITUATION. THE FIRST SIGN OF FAILURE WAS A HEAVY BURNED OIL ODOR. THE ODOR WAS CAUSED BY A LOT OF OIL POURING OVER THE EXHAUST PIPE WHICH ALSO WAS A DANGER OF FIRE. AFTER INSPECTION MECHANIC FOUND THAT THE TRANSFER CASE HAD A LEAK AND THE COUPLING SPLINES BETWEEN THE TRANSMISSION AND THE POWER TRANSFER CASE AND THE RIGHT DRIVESHAFT WERE EXTREMELY CORRODED, THIS CORROSION WAS NOS EVIDENT FROM OUTSIDE BECAUSE EITHER THE TRANSMISSION AND THE TRANSFER CASE ARE MADE OF ALUMINUM AND THE DRIVESHAFT IS INSERTED THROUGH THE POWER TRANSFER UNIT INTO THE TRANSMISSION, BUT FOR UNKNOWN REASONS, THE TRANSMISSION OUTPUT AND TRANSFER CASE INPUT PARTS WHICH ARE MADE OF STEEL ARE BADLY CORRODED AND GOT SEVERELY WORN WITH A LOT OF RUST ACCUMULATION IN PLACE, WHICH IN TIME WILL CAUSE A TRACTION LOSE THAT WOULD SEVERELY COMPROMISE DRIVING SAFETY. MAZDA ISSUED A BULLETIN TO ADDRESS THE POWER TRANSFER CASE UNIT BUT IS LIMITED TO 7 YEARS OR 90000 MILES WHICH IS A LOW MILEAGE FOR A PROBLEM LIKE THIS TO DEVELOP AND WHEN THE OWNER TRIES TO TAKE ACTION MAZDA WILL NOT COVER THE REPAIRS. I THINK THI IS A MANUFACTURING QUALITY CONTROL ISSUE SINCE ITS COMPLETELY BEYOND THE ACTIONS OR FAILURE OF THE OWNER TO FOLLOW A PROPER MAINTENTANCE SCHEDULE SINCE THE OWNERS MANUAL DOESNT SAY ANYTHING ABOUT IT. HTTPS://STATIC.NHTSA.GOV/ODI/TSBS/2014/CSC-10055535-7382.PDF MAZDA DOES NOT HAVE A SERVICE SCHEDULE FOR THIS PART AND IS CONSIDERED TO BE MANTENTANCE FREE HOWEVER, IF THE ISSUED THE SERVICE BULLETIN IS BECAUSE THEY KNOW THIS PART HAS POTENTIAL ISSUES. THE INVOLVED PARTS SHOULD BE REPAIRED BY MAZDA SINCE IS A DESIGN OR MANUFACTURE PROBLEM. THANK YOU FOR YOUR ATTENTION TO THIS MATTER.