NHTSA Complaint #11709508 — 2022 MAZDA CX-5

Brake rotors on all four wheels measured below minimum thickness specification at only 17,000 miles, requiring complete replacement of all rotors and pads. Rotors replaced at Koch Mazda (Easton, PA) on January 7, 2026 and no longer available for inspection. SAFETY RISK: Rotors below minimum spec have reduced structural integrity and heat dissipation capacity, creating risk of warping, cracking, or failure during emergency braking or sustained braking. Under-spec rotors can cause brake fade, increased stopping distances, and potential catastrophic failure. At 17,000 miles, this represents premature failure of a critical safety system. DEALER CONFIRMATION: Koch Mazda initially charged $89.99 for diagnostics claiming "nothing wrong" despite customer providing TSB 04-003/24 documentation. After formal complaint, dealership measured rotors below minimum spec and replaced all four rotors and pads as "non-warranty goodwill repair" (value $1,184.97). Calling it "goodwill" rather than warranty avoids documenting as defect claim. Dealership stated Mazda corporate approved the goodwill repair, indicating manufacturer awareness of widespread defect being managed case-by-case rather than through recall. WARNING SYMPTOMS: Popping/clicking noise when first moving forward or reverse after sitting idle. This symptom is specifically described in Mazda TSB 04-003/24 as caused by deteriorated grease between brake pads and shims. SYSTEMIC PATTERN: Research reveals hundreds of similar complaints across 2013-2025 CX-5 model years involving premature rotor/pad failure at 11,000-35,000 miles. TSB 04-003/24 addresses this exact pattern across multiple model years, confirming manufacturer awareness. Normal rotor life is 50,000-70,000 miles; failure at 17,000 miles suggests manufacturing defect, improper heat treatment, or design flaw affecting entire CX-5 brake system across 12+ model years.