2009 MAZDA MAZDA6 Structurebody Problems

FRONT SUBFRAME AND ENGINE SUPPORT RUSTED OUT TO THE POINT THAT IT WAS CRACKED AND BROKEN HAD TO BE REPLACED BEFORE IT RESULTED IN CATASTROPHE LOSS OF CONTROL. I HAD TO REPLACE THIS PART @ $2500 JUST TO KEEP CAR DRIVE ABLE. I'VE SINCE SOLD CAR AFTER FRAME WAS REPLACED WITH NEW OEM PART.

RUSTED SUBFRAME MECHANIC'S INSPECTION AT 100,000 MILES REVEALED SEVERE RUSTING OF SUBFRAME. THIS IS A SAFETY CONCERN BECAUSE IF IT BREAKS IT WOULD ALLOW THE ENGINE AND TRANSMISSION TO FALL OUT OF PLACE. I HAVE ORDERED A REPLACEMENT PART BUT IT IS UNAVAILABLE UNTIL JULY. IN THE MEANTIME, IT FEELS AS THOUGH I AM DRIVING A TIME BOMB. I AM FILING THIS COMPLAINT BECAUSE IT SEEMS ABNORMAL FOR A STRUCTURAL COMPONENT TO ROT OUT SO QUICKLY AND BECAUSE IT SEEMS TO BE A COMMON PROBLEM FOR THIS MAKE AND MODEL.

THE SUBFRAME OF MY 2009 MAZDA6 COMPLETELY ROTTED OUT FROM THE INSIDE AND THE VEHICLE BROKE DOWN DURING NORMAL USE. ON WEDNESDAY, MAY 2ND, A MAZDA DEALERSHIP REPLACED MY ROTORS, PADS, AND NOTICED THE CAR WAS PULLING TO ONE SIDE SO THEY CORRECTED THE ALIGNMENT. DURING THIS TIME THEY IDENTIFIED A NORMAL LEVEL OF RUST ON THE SUBFRAME BUT WAS NOT CONCERNED BY ANY OTHER SIGNS OF FAILURE. LESS THAN 10 MILES AFTER LEAVING THE DEALERSHIP THE SUBFRAME CRACKED, MY FRONT PASSENGER WHEEL CV AXIL DISCONNECTED AND THE CAR WAS INOPERABLE. THANKFULLY I WAS GOING ONLY 35 MPH, DOWN A STRAIGHT, PAVED CITY ROAD, AND NOT ON THE HIGHWAY. I FEAR THAT AT HIGHER SPEEDS THE CAR WOULD HAVE GONE OFF ROAD OR WORSE FOR WHEN THE SUBFRAME BROKE THE CAR JERKED HEAVILY TO THE RIGHT THEN COMPLETELY STOPPED. I BELIEVE THE DEALERSHIP PROVIDED QUALITY SERVICE AND DUE TO THE...

I WAS DRIVING TO A MEDICAL APPT ON LOCAL ROADS WHEN I NOTICED A THUMPING SOUND FROM THE FRONT LEFT, AS IF THE TIRE WERE GOING FLAT. I STOPPED AND INSPECTED THE TIRE AND FOUND NO PROBLEMS, SO I CONTINUED ON TO THE APPT LESS THAN A MILE AWAY. LEAVING THE APPT I FELT THE CAR SUDDENLY PULLING SHARPLY TO THE RIGHT, AND THE DSC-OFF LIGHT CAME ON. TURNING RIGHT CAUSED A LOUD SQUEAKING NOISE. I DROVE IMMEDIATELY TO A MAZDA DEALERSHIP THAT WAS FORTUNATELY ONLY A MILE OR SO AWAY. THEY EXAMINED THE CAR AND FOUND THAT IT IS UNSAFE TO DRIVE DUE TO SEVERE RUSTING OF THE FRONT SUBFRAME (RIGHT SIDE). THEY SAID THAT IF I HAD HIT A POTHOLE THE RIGHT FRONT TIRE MAY HAVE BROKEN OFF, ENDANGERING MY LIFE AND THE LIVES OF OTHERS. THE DEALERSHIP WAS UNABLE TO LOCATE A USED SUBFRAME, AND NEW SUBFRAMES...

TL* THE CONTACT OWNS A 2009 MAZDA 6. WHILE THE VEHICLE WAS BEING DIAGNOSED FOR A CYCLICAL NOISE IN THE ENGINE, THE CONTACT WAS INFORMED BY LANNAN MAZDA (720 ROGERS ST, LOWELL, MA 01852, (978) 454-9300) THAT THERE WAS SEVERE RUST AND SEPARATION OF THE SUBFRAME IN THE ENGINE COMPARTMENT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 132,000. THE VIN WAS NOT AVAILABLE.

WHILE DRIVING AT HIGHWAY SPEED (55-65MPH) THE STEERING WHEEL BEGAN PROGRESSIVELY ROTATING COUNTER-CLOCKWISE WITH THE VEHICLE REMAINING STRAIGHT. THE DYNAMIC STABILITY CONTROL TURNED OFF AS IF THE VEHICLE WAS OUT OF CONTROL AND THE VEHICLE ACTED AS IF IT WERE ON ICY/SLICK SURFACES NO LONGER PROVIDING SUPPORT TO THE DRIVER. THE BRAKING SYSTEM BEGAN TO STRUGGLE NEARLY CAUSING AN ACCIDENT ON THE OFF RAMP OF THE EXPRESSWAY CAUSING A FISHTAIL WITH THE ABS ATTEMPTING TO ENGAGE. AT THIS POINT THE STEERING WHEEL WAS REGISTERING STRAIGHT' WITH THE STEERING WHEEL TURNED APPROXIMATELY 30 DEGREES LEFT. SOMEHOW AT SPEEDS LESS THAN 15 MPH THE VEHICLE WAS DRIVEN TO THE LOCAL MAZDA DEALERSHIP WHERE IT HAS A SERVICE HISTORY FOR AN EMERGENCY SERVICE INSPECTION. A TEST DRIVE WITH A SERVICE REPRESENTATIVE SUPPORTED THE OWNER'S COMPLAINTS OF A SEVERE SAFETY CONCERN WITH RIGHT TURNS CAUSING A SIGNIFICANT 'GRINDING'/METALLIC DRAGGING SOUND AS IF THE VEHICLE'S...

I HAVE BEEN TAKING MY 2009 MAZDA 6 (60,000 MILES) TO THE DEALER FOR REGULAR MAINTENANCE SINCE I BOUGHT THE CAR. IT GETS TAKEN TO THE DEALER TWICE A YEAR FOR REGULAR OIL CHANGES AND TIRE ROTATIONS. ON THE MOST RECENT OIL CHANGE AND TIRE ROTATION, THEY SAID THAT THE FRONT CROSSMEMBER ENGINE CRADLE HAD SEVERE CORROSION AND RUSTED THROUGH. IF THE REPAIR IS NOT DONE AND THE WHEN, NOT IF, THE PART FAILS THE ENGINE MAY FALL OUT OF THE CAR AND THE FRONT TIRES WILL FAIL TO STEER. THIS IS A MAJOR SAFETY LIABILITY! A CRUCIAL COMPONENT TO SUPPORT THE MOST IMPORTANT PART OF THE CAR SHOULD NOT RUST AND FAIL ON A CAR THAT HAS LESS THAN 7,000 MILES DRIVEN PER YEAR.

ENGINE CRADLE BROKE, CAUSING THE STEERING TO LOCK UP. I WAS DRIVING APPROXIMATLY 45 MPH STRAIGHT ON A RURAL STATE ROUTE, I BRAKED SLIGHTLY TO SLOW DOWN THEN THE CAR JUST LOCKED UP AND SLID OFF THE ROAD. HAD IT TOWED AND FOUND THAT THE ENGINE CRADLE WAS BROKEN. AFTER DOING SOME RESEARCH I FOUND THIS TO BE A PROBLEM WITH THIS YEAR AND MODEL.

PASSENGER SIDE DASHBOARD HAS BECOME STICKY/MELTING

THE VEHICLE IS 8 YEARS OLD, HAS 133000 MILES, HAS HAD 1 OWNER, AND HAS ALWAYS BEEN HOUSED IN A GARAGE. DESPITE THIS, THE FRONT SUB-FRAME ASSEMBLY IS RUSTED AND ROTTING AND NEEDS TO BE REPLACED. I ORIGINALLY BROUGHT THE VEHICLE IN TO GET THE RIGHT INNER/OUTER TIE RODS AND TIE ROD BOOT REPLACED, BUT ONCE ON A LIFT A MECHANIC IDENTIFIED THE PERVASIVE RUST. THE MECHANIC SHOWED ME THAT THE RUST/ROT WAS SO BAD THAT THE MOUNT POINT FOR THE TIE ROD ASSEMBLY NO LONGER ATTACHES TO THE SUB-FRAME.

TL* THE CONTACT OWNS A 2009 MAZDA 6. WHILE DRIVING APPROXIMATELY 30 MPH, THE STEERING WHEEL HAD TO BE TURNED ALL THE WAY TO THE LEFT IN ORDER TO MAINTAIN A STRAIGHT LINE. THE CONTACT PULLED THE VEHICLE OVER IN A PARKING LOT AND HEARD A SCREECHING SOUND WHEN THE BRAKES WERE APPLIED. THE STEERING WHEEL WENT ALL THE WAY TO THE RIGHT. THE CONTACT CALLED AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE SUBFRAME WAS ROTTED OUT AND THE FRONT PASSENGER SIDE SWAY BAR LINK NEEDED TO BE REPLACED. THE DEALER, MAZDA OF BEDFORD IN BEDFORD, OHIO, WAS CONTACTED BY PHONE AND ADVISED THE CONTACT TO BRING IN THE VEHICLE. THE MANUFACTURER WAS CONTACTED AND PROVIDED CASE NUMBER: 1-836240644. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.

I WENT FOR AN OIL CHANGE AND FOUND OUT THAT THE FRAME THAT HOLDS THE ENGINE IN PLACE WAS COMPLETELY ROTTED OUT AND THAT MY ENGINE COULD FALL OUT AT ANY GIVEN TIME. ALSO, BECAUSE OF THE ROT, THE ROD THAT SHOULD BE ATTACHED TO THE STEERING WAS NOT ATTACHED BECAUSE THE BOLTS HAD NOTHING TO ADHERE TO. THIS COULD HAVE RESULTED IN ME DRIVING WITH MY DAUGHTER AND LOSING MY STEERING AND POSSIBLY GETTING IN A FATAL ACCIDENT. THE CAR IS IN THE SHOP AS IT IS NOT ABLE TO BE DRIVEN PER MY MECHANIC FOR SAFETY REASONS AS WELL AS FAILING INSPECTION FRO THIS. PLEASE CONTACT ME AS SOON AS POSSIBLE AS I DO NOT HAVE ANY TRANSPORTATION AND I WORK FULL TIME. I CAN BE REACHED AT [XXX]. OR MY MECHANIC AT HOMETOWNE AUTO, [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C....

SYMPTOMS: ALIGNMENT OF THE CAR WAS NOT CORRECT, STEERING WHEEL NOT CENTERED, WHEN BREAKING TIRE GRIP WAS LIMITED. RAIN EXAGGERATED THE SYMPTOMS, CAR WOULD SLIDE EASY AND WAS DIFFICULT TO STOP(TIRES ARE IN EXCELLENT CONDITION). RIGHT FRONT WHEEL CAMBER SIGNIFICANTLY OUT. VISUAL INSPECTION OF THE TIRE INDICATED CAMBER WAS NOT CORRECT. INVESTIGATION INTO POTENTIAL WEAR ITEMS WAS COMPLETED SEARCHING FOR THE POSSIBILITIES OF WORN LOWER BALL JOINT, SHOCK TOWER CONNECTIONS AND STEERING RELATED COMPONENTS. ALL ITEMS APPEARED NORMAL. FURTHER INVESTIGATION TO CONNECTIONS OF THE LOWER CONTROL ARM REVEALED SIGNIFICANT CORROSION AND SEPARATION OF WELDED STEEL ON THE ENGINE CRADLE(ALSO KNOWN AS FRONT SUB FRAME/FRONT CROSS MEMBER/FRONT K-FRAME) CORROSION WEAKENED THE CROSSMEMBER SUFFICIENTLY TO ALLOW NORMAL EVERYDAY DRIVING TO BEND THE CROSSMEMBER AND CREATED THE OUT OF ALIGNMENT AND CAMBER ISSUE. CONTINUING TO DRIVE IN THIS STATE COULD HAVE RESULTED IN THE LOWER CONTROL ARM BREAKING THE CROSSMEMBER COMPLETELY AND LIKELY...

THE FRONT ENGINE CRADLE/SUBFRAME, LOWER CONTROL ARMS IS RUSTED/CORRODED TO THE POINT THAT I WAS ADVISED CAR WOULD NOT PASS INSPECTION AND THAT IF PARTS FAILED, ENGINE WOULD FALL UNDER CAR AND I COULD LOOSE ALL STEERING/BRAKES. PER REQUEST FROM MAZDA CAR WAS TAKEN TO DEALER WHO CONFIRMED EXTENT OF CORROSION. THIS CORROSION DID NOT HAPPEN IN AN INSTANT AFTER WARRANTY BUT STARTED AND CONTINUED TO WORSEN DURING WARRANTY PERIOD. ONLY SAW THIS WHEN NON-DEALER WAS PUTTING NEW TIRES ON CAR AND NOTED EXTENT OF CORROSION.

DASHBOARD IS MELTING; VERY STICKY TO THE TOUCH EVEN WHILE IN THE GARAGE.

HORN HAS ACTIVATED RANDOMLY FOR YEARS NOW, THE FIRST INSTANCE OCCURRING ON OR ABOUT JULY, 2013. I HAVE BROUGHT THE CAR INTO THE DEALERSHIP MANY TIMES FOR THIS. EACH TIME THEY SAID THE DOOR LATCH WAS FAULTY AND SETTING IT OFF. I HAVE HAD 3 DOOR LATCHES REPLACED WITH THE MOST RECENT BEING DONE ON 5/2015. IN AUGUST 2016, THE HORN STARTED ACTIVATING RANDOMLY AGAIN. THE DEALERSHIP SAID THAT THEY FOUND "CODES" ON THE 3 DOOR LATCHES THAT WERE ALREADY REPLACED! CLEARLY THERE IS A DEFECT SOMEWHERE WITH THE DOOR LOCKS OR ITS ELECTRICAL COMPONENTS. THIS POSES A SEVERE SAFETY HAZARD AS A CHILD CAN OPEN THE DOOR LOCK AND FALL OUT WHEN THE VEHICLE IS MOVING IF THE LOCK IS NOT WORKING.

SUBFRAME RUSTED STRIGHT THRU ON THE RIGHT SUPPORT POINT. LEFT SUPPORT POINT HAD NO RUST AT ALL.. APPROX 96000 MILES ON THE CAR, AND THIS RUST WAS FOUND BY MY MECHANIC AFTER REPLACING THE NEUTRAL SAFETY SWITCH..THE RUST IS HARD TO DETECT BECAUSE THE PLASTIC COVERS , THAT COVER THE SUBFRAME.

RUBBER AROUND SMALL REAR WINDOW, NOT THE ONE THAT OPENS, HAS LOST MOST OF THE RUBBER. NOTICED THIS WHILE WASHING THE VEHICLE. THE REMAINING RUBBER DID NOT SEEM DRY ROTTED BUT IT PULLS OUT EASILY AND SIGNIFICANT AMOUNT IS ALREADY MISSING.

DASH BOARD MELTING AND BECOMES STICKY

THE DASHBOARD STARTED TO MELT A FEW MONTHS AGO, AROUND MAY. NOW THE DASHBOARD IS PERMANENTLY STICKY AND THERE IS A SMELL ARISING. IN ADDITION, DASHBOARD CREATES A GLARE ON THE WINDSHIELD WHICH AFFECTS THE VISIBILITY WHILE DRIVING. IF YOU PLACE SOMETHING ON IT, THERE IS A BLACK RESIDUE THAT COMES OFF ALONG WITH IT. THE MELTED DASHBOARD IS SHINY AND STICKY.

TL* THE CONTACT OWNS A 2009 MAZDA 6. THE CONTACT STATED THAT THE DASHBOARD WAS MELTING. AS A RESULT, THE SUN CAUSED A GLARE WHICH IMPAIRED THE CONTACT'S VISION. THERE WAS ALSO A STICKY SUBSTANCE PRESENT. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT ALSO STATED THAT THE VEHICLE'S ALARM ACTIVATED RANDOMLY. THE FAILURE RECURRED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSTIC TESTING. THE MECHANIC STATED THAT THE REAR DRIVER SIDE DOOR FAILED TO CLOSE AND THE DOOR LATCH WAS REPLACED. THE FAILURE RECURRED AND THE FRONT PASSENGER SIDE DOOR LATCH WAS REPLACED. THE CONTACT WAS MADE AWARE OF NHTSA CAMPAIGN NUMBER: 13V425000 (LATCHES/LOCKS/LINKAGES); HOWEVER, THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 40,000.

TL* THE CONTACT OWNS A 2009 MAZDA 6. WHILE DRIVING APPROXIMATELY 5 MPH, A LOUD BANGING NOISE EMITTED FROM THE FRONT OF THE VEHICLE. THE CONTACT DISCOVERED THAT THE FRONT PASSENGER SIDE WHEEL WELL RUSTED AND CAUSED THE SUSPENSION TO FAIL. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 190,000.

DASH OF VEHICLE ON THE PASSENGER IS BEGINNING TO MELT. IN MELTING, THE DASH NOW HAS A GLOSS APPEAREANCE THAT, IN THE RIGHT LIGHT, CREATES A GLARE WHILE DRIVING. THIS CAN MAKE IT DIFFICULT FOR THE OPERATOR TO SEE. *TR

TL* THE CONTACT OWNS A 2009 MAZDA 6. THE CONTACT STATED THAT THE DASHBOARD ON THE VEHICLE STARTED TO MELT. THE VEHICLE WAS TAKEN TO THE DEALER BUT THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE DEALER STATED THERE WAS NOTHING THAT COULD BE DONE OUTSIDE OF REPLACING THE ENTIRE DASHBOARD. THE FAILURE MILEAGE WAS 104,344.

THE ENTIRE PASSENGER SIDE DASHBOARD IS GOOEY, STICKY BLACK. IF YOU TOUCH IT GETS ALL OVER YOUR HANDS, AND EVERYTHING WILL STICK TO IT. IT APPEARS TO BE MELTING AWAY. THIS STARTED A FEW YEARS AGO. RECENTLY I NOTICED THE REAR HEADLIGHTS LOOK AS IF THEY ARE WARPED FROM THE INSIDE, AS IF IT WAS A MELTED CANDLE. *TR

TL* THE CONTACT OWNS A 2009 MAZDA A6. THE CONTACT STATED THAT THE DASH BOARD WAS MELTING. THE MANUFACTURER WAS CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 50,000 AND THE CURRENT 75,000.

DRIVER SIDE FRONT DOOR WOULD NOT LATCH, INSPECTED TO FIND ALL THREE DOOR LATCH MOUNTING SCREW WERE MISSING, AND THE DOOR LATCH WAS FALLING DOWN INSIDE THE DOOR. VERY DANGEROUS, AND I WAS STRANDED IN A PARKING LOT WITH A DRIVER DOOR THAT COULD NOT BE LATCHED. *TR

DRIVER SIDE FRONT DOOR WOULD NOT LATCH UPON ENTRY TO THE VEHICLE. INSPECTION SHOWED THAT ALL 4 SCREWS WERE MISSING FROM THE LATCH MECHANISM. INSPECTION OF THE OTHER 3 DOORS SHOWED THAT UP TO 3 OF THE 4 SCREWS WERE MISSING FROM THEM. EVERY DOOR HAD AT LEAST 1 MISSING SCREW. *TR

WHILE DRIVING ON HIGHWAY AT 55 MPH THE PASSENGER DOOR OPENED . PASSENGER DIDN'T FALL OUT DUE TO SEAT BELT. FOUND THAT THREE SCREWS FELL OUT OF DOOR LATCH. REPLACED SCREWS, NOW DOOR CAN NOT BE OPENED FROM OUTSIDE. *TR