Mazda6 Maintenance and Repair

jstandefer

Some people believe the problem is fixed. Some people don't. This "staining" is still being found on vehicles with build dates as recent as last month. Mazda claims it was fixed in July, but the range of the so-called repair only covers vehicles that were built up to May. Try going to 4DoorZoom and decide for yourself.

wonderwall

if you're looking for a car without a lot of problems i wouldn't be looking at a Jetta... just got outta one and into a Mazda Protégé 5.

bostongio

Yes, Mazda has released a TSB for the issue and owners who have the problem are getting the fix. Mazda has said that it has changed its manufacturing procedure to ensure this doesn't happen with newer models, but it is a good idea to double-check the dealers lot to be sure.

I pulled the trigger on the new 5-door coming in March, 2004 and put a deposit down. It's a sweet car and nothing comes close to it feature-wise and quality-wise for the price. VW is not known for building high-quality cars, sorry.

coakleysd

Is anyone out there experiencing an audible noise when the brakes are applied on hard left turns under 5 mph? A squeaking noise is also audible when reversing in the opposite direction. This problem has persisted for months, but dealer is unaware of this issue elsewhere.

Need your help.

Stafford

mazdafun

Both are sound-dampening measures. You'd need to remove the pads to check.

arockwel

Yes. I've had the same exact problem. The dealer is replacing the front pads and I think the rotors on my 6i. Something wasn't fitting properly is about all I can tell you. Have them fix it as I think it will get worse...

wantapassatnow

Is this rust -- sorry, "stain" -- problem exclusive to the 6, or is it in the 3 and other Mazdas too? Thanks!

jstandefer

Just to give everyone an update:

I have been in discussion with a metallurgy lab regarding testing ability, procedures, timeframe, and pricing. I will now discuss the legal do's and don't's with a couple of attornies to be sure money is not wasted.

Until everything is finalized and testing is ready to begin, I will not release the name of the laboratory or their pricing. I don't want them to be inundated with calls, letters, or e-mails from owners, manufacturers, or media. You never know who is watching and reading.

My goal is to test 6 vehicles from different locations throughout the county, ranging in build dates before and after Mazda's magical date. I would love to test more, but there are financial limitations and these tests are not cheap.

Testing will be conducted on the discoloration, the soapy solution residue, the paint, and any commonality and reaction between them. Equipment and procedures used will be a Field Emission Scanning Electron Microscope (FE-SEM), Energy Dispersive X-Ray Spectroscopy (EDX), Fourier Transform Infrared Spectroscopy (FTIR), and X-ray Photoelectron Spectroscopy (XPS or ESCA).

Our biggest hurdle will be finding a way to cover the costs. This will really test the resolve of owners. Should the test come back positive for rust and negative for lubricant-caused corrosion, we will pursue litigation to recuperate the costs.

jstandefer

This only affects Mazda6 vehicles sold in the United States and Canada (built at Auto Alliance International, Flat Rock, Michigan). All other Mazda6's and Mazda vehicles are not affected.

wantapassatnow

Thanks for the clarification!

*now pondering the Mazda 3*

aromas

I'm getting that squeaking noise too every so often but am preoccupied with this stupid rust to bother getting it checked out. I'll mention it when I bring my car in to get the seats replaced.

There's one thing I now have learned I will never buy a 1st year car EVER AGAIN. I can't beleive how many problems I've had with this car since I bought it in March.

1. Rust, rust, rust everywhere.
2. A\C selector switch needed to be replaced.
3. My cloth seats are fraying badly and have to be replaced.
4. Squeaking noise with the brakes. With my luck I'll need the rotor replaced.
5. The 2 recalls.
 
My car is gonna end up spending more time in the shop than my driveway. The worst thing is the loaner Protege I get is so dirty inside you don't want to sit in it.

Anybody with their eye on the Mazda 3, buyer beware, whether it's made in Japan or not.

jstandefer

This has cropped up in the past 2 weeks. Whenever I am braking gently while the wheels are turned either right or left, the right front brake moans loudly. It doesn't do this when going straight, backing up, or braking moderately while turning. It mainly happens while turning into a parking space.

I'll bring it to the dealer's attention next time it goes in for another "vacation." Everybody runs when they see my car pull into the service drive! The last service advisor had to type up 4 pages of problems! It's so sad it is hilarious... then again, I'm drugged up on cold medications!

aromas

jstandefer: I think both our cars must have been separated at birth. Keep a close eye out on those seats. Yikes I think I jinxed you.

buggywhip

jstand, I read about your Mazda6 probs on that other car opinion website; you really got a lemon and it's not fair. Nowadays, 1st yr cars don't have such probs--even the new Caddy CTS hasn't been that bad. This just strikes me as bad and lazy engineering. I was planning on getting a 6, but I think I'll stick with my Olds.

mazdafun

It'll kill even the best of designs. Jerry seems to have the worst 6 ever made.

Anyone else read that management article? Seems AAI has had difficulties in the past with their employees not getting into the quality assurance program (amongst others). Doesn't surprise me.

jstandefer

I really don't have much against the 6 in general, other than the rust and electronic throttle. Overall, the 6 is a wonderful car, but I recommend waiting to get one while the bugs get worked out... My personal 6 has just been one nightmare after another and I am researching the Lemon Law in depth. My car is just about to trigger it, in many ways.

Do I want another 6? With this rust issue, no. If the rust issue didn't exist, I would consider another one, but the insecurity now embedded in the back of my head with this car will probably get the better of me and I will get something else. I'm sure another 6 would be just fine, but it's an emotional thing. Although I might consider the new 3, I am a bit disillusioned with new cars right now, so I might just get some beater car to drive for a while until I feel comfortable again. Then again, I always wanted a Miata, so that just may be my next car. I have the Protege5 for practicality.

newmz6owner

Sorry I have not read any further, but when I read the first page of this discussion I couldn't pick my mouth up off the floor. I just purchased a 2004 Mazda 6 last week and unfortunatley did not know about Edmunds discussion groups. If I had known, I think I'd still be driving my '98 Cavalier.

Who's beeing effected by this rust problem? All I've read so far is if the car came from the Flat Rock, MI plant. Which mine did. If someone out there could give me some good news or an idea of where I could go to find out more information, I would really appreciate it. For the time being I will read on.

grove4

Just go to google and type mazda6 rust and it is all over the place with pics too.Sorry to dissapoint.Maybe you are a lucky one but chances are you will have it too.

glideslopes

Chances are you'll be ok with no rust. My 6s AT has been flawless over 9,000 hard miles. The only issue I have had other than the rust (not minimizing it) was a couple of loose bolts on the rail that holds the drivers window. It would make a click sound when going up.

The vast majority of owners have not had any mechanical issues. Yes of course there are some with brake noises, clunks, and rough shifting AT's. Remember, if you come in here, for the most part it is the same 25-30 people with complaints. Myself included. How many cars are on the road?

The only thing I would have done differently is wait for the 04 model if I could do it over again.

If Mazda does not repair my car satisfactorily will I sell it and walk away? It's a good possibility.

Negatives aside, there simply is not a car in it's class and price that could put a larger grin on my face every time I drive. Six months from now you will enjoy driving it more than today.

I wish you a corrosion free experience.

Mark.

chatton

Include me in the rust club. Checked today and the rust spots are clearly there. Didn't even have to look hard. Here's the info on the car:

VIN M43552, purchased June 17, Sepang Green, I live 30 miles west of Philly, PA.

Car was purchased to replace a beloved 18 month old P-5 that was totaled when a tractor trailer behind me wanted the same part of the road i was in while at a red light. The car was trashed, but the passenger cell remained practically undamaged, and I walked away.

I plan to take my 6 in to be "repaired" for the rust, TSB in hand....

c_hunter

I would advise you to pass on the metallurgy lab and instead find a consultant or retired engineer with experience in auto body design and manufacturing. This is clearly more of a fabrication issue, and I don't think you need metallurigical analysis -- this is obviously rust coming from unsealed raw steel, no matter how you look at it. Hook up with an expert who knows his stuff, this is what will matter in any legal proceeding.

Craig

mazda6s

I agree. It's obviously rust, so there's no sense in proving that. What you want to prove is that the door frames were not finished (sealed and painted) properly and that it is NOT the so-called "soapy solution" causing "staining". Then Mazda has to fix the rust under warranty because it's a manufacturing defect. And before anyone says this is not required because it's not rust penetration, I'll say it is covered under warranty because it's an obvious defect in workmanship that means Mazda failed to deliver a completely painted car, which is a reasonable expectation (and a jury will agree with that).

glideslopes

Is it possible for a door to be located and purchased at a auto recycling facility? It could be taken apart and verified?

I would be willing to contribute provided there was group involved.

Mark.

seaf

should be done, but maybe not too thoroughly due to cost issues. But proving that it's a rust is a good starting point.

midwesttrader

Read on another forum that Mazda Tech Services sent a bulletin yesterday to the dealers advising them to perform the fix on cars on their lots first before taking any customer cars in for service.

The same owner also reported the first "staining" I've heard of inside his fuel door. Has the soapy solution spread?

pubdef

"What you want to prove is that the door frames were not finished (sealed and painted) properly and that it is NOT the so-called "soapy solution" causing "staining". Then Mazda has to fix the rust under warranty because it's a manufacturing defect."

Say what you will about this situation, and I've said a lot, but despite all the issues, Mazda IS doing their "fix" under warranty. That's a done deal. It's been done under warranty to several cars already, including mine (which I'll report on and post pictures of soon. For now, let's just say I'm pleasantly suprised at the look of the repair, but skeptical as to its longevity...)

windchime

I went to the dealer (Gallery Mazda, Norwood, MA) today for regular service and planned on setting an appointment for the rust fix. the service technician insisted there was no fix yet for the staining. I told him several times about the TSB, but he didn't acknowledge. We finally called the service manager and he agreed with me, but that they hadn't performed this on any vehicle yet. They offered to do it today, and make me the first; I said I would make an appointment. They told me it would take all day. Every time I used the word rust, the service manager went way out of his way to correct me and call it staining. He said: "It is definitely not rust." I asked if this was a permanent fix. he said: "That's what they say."

Anyway, I will have mine done soon.

gee35coupe

car...And ask what put the "stain" there. As he gets the deer in headlights look tell him to prove to you it's staining and not rust.

That ought to make for a good post.

baggs32

"The same owner also reported the first "staining" I've heard of inside his fuel door. Has the soapy solution spread?"

Either that or he/she scratched it with gas filler nozzle thingy, a ring, keys, etc...

jstandefer

"I would advise you to pass on the metallurgy lab and instead find a consultant or retired engineer with experience in auto body design and manufacturing. This is clearly more of a fabrication issue, and I don't think you need metallurigical analysis -- this is obviously rust coming from unsealed raw steel, no matter how you look at it. Hook up with an expert who knows his stuff, this is what will matter in any legal proceeding."

Thanks for the advice. I did consider this, but I think the metallurgy lab is the first place to go. Since we are making the claim that it is rust, it is our burden of proof. The cost involved is certainly more than we would like (1 cent is more than we would like), but this is the route that must be taken in our effort to get a proper fix. If it is proven that it is rust and that the "soapy solution" didn't cause the staining," then our burden of proof has been fulfilled. It will then be Mazda's responsibility to rebuff the results with more convincing data or admit to the rust and fix the problem in a more acceptable fashion.

Without the metallurgy test, Mazda's current "fix" will stand. Plus, this is probably a cheaper route than hiring a consultant. A consultant's first move will probably be to get the tests done to prove the staining is rust bleed and not a discoloration caused by the assembly lubricant.

mazda6s

Should be fairly easy to prove. Either there is iron oxide present or not!

replay

let me know whenever you get a cost figure on the lab. i'm more than willing to chip in

jstandefer

"Should be fairly easy to prove. Either there is iron oxide present or not!"

True. However, you can find iron oxide presence on just about every external panel of the car. The severity of the presence is what we're after.

"let me know whenever you get a cost figure on the lab. i'm more than willing to chip in"

Thanks. It looks like we probably won't be able to recuperate the costs unless it is part of a suit for damages. I'm still working on this... I knew this would be a bad time for a new dog! Ugh! Bad dog! Bad dog!

tcichon

I have the 2003 Mazda6 4 cyclinder purchased April 2003 has 5000 miles on it. Saw the engine light come on then the oil light, I have had 2 oil changes. When I got to a red light it was dead. Had to be towed to the dealer. The mechanic told me that a bolt was not torqued or tight enough that came loose caused the oil pump to stop and shut down the motor. Today they have to get parts from Canada, oil pump, drive gear and nut and something else. I was not real happy. I will know more when the car is fixed and post more details. I just want to know if anyone has broken down yet?

mazda6s

You'd be even less happy if the oil pump had stopped and the engine had not shut down!

newcar31

My dealership still has not called me back regarding the TSB. The service manager told me before the TSB was issued that he would call me as soon as he heard back from Mazda. Still, no call. I'm going to wait until he calls, because I'm not going to call them again.....

As far as tcichon's car shutting down is concerned, does the Mazda6 shut down the engine when low oil pressure is detected, or did the car shut down because of high friction created by not having oil?

tcichon

My Mazda broke down because of a loose nut that cause the drive pulley to disengage and stop the oil pump. I spoke to my salesman last night and he said the car is designed to do that. Which if that happens it is best to have the car shut down. They are replacing the oil pump, front over and drive gear and nut.

mazda6s

Does anyone know for sure if the rust issue is just on 03 models or has it been seen on 04 models? I think I've seen the answer to this posted here but don't remember the details.

dondilio

Hey guys, I just took my 6 to the dealer yesterday to get the CEL recall and to get an oil change and asked about the claking sound coming from the suspension. The service advisor told me that the had identified a defective part and that they had ordered lots of them. I have an appointment for Dec 1. Ill keep you posted. By the way, no rust yet on mine.

tcichon

Your rude comment was not appreciated "You'd be even less happy if the oil pump had stopped and the engine had not shut down!
Everyone commenting on this website just wants to help other Mazda 6 owners. Rule of thumb. If you don't have nothing nice to say don't say anything at all!

lmp180psu

I think Mazda6s was just trying to say that you were lucky that nothing worse happened to your car than what happened. I didn't think the comment was meant to be rude. Mazda6s' posts are not like that at all from what I have seen.

dinu01

I echo #642 - it wasn't meant to be rude. It could have potentially been worse if the engine did not stop.

Dinu

loupie

I've had my 6i w/sport package for about 5 months, have 15K on it, and it's been a great car overall. I've had the 2 recalls taken care of, and I still have the brake noise while turning right at slow speeds, and also have the suspension (light) clunking problem, but I'll get them resolved next time It's convenient to leave my car at the dealer for a day or two. Most new cars in their 1st model year have a few issues... I bought the Cirrus when it first came out, and t was a mess... after working the kinks out it was trouble-free to 80K when I traded it. I think the 6 is a winner, and after Mazda works out the bugs it should be pretty much trouble free.

mazda6s

My comment was in no way intended to be rude, and I'm sorry you interpreted it that way.
Apparently the Mazda6 has a sensor for oil pressure and if the pressure drops too low the computer shuts down the engine to avoid serious engine damage requiring a rebuild. This is a very good thing and a feature that every new car should have! It would have been much, much worse if the engine had not shut down.

aromas

O.K. time for a group hug. Ahhh everybody feel better now. Mazda6s you can make fun of my rust if you want, I won't get mad I promise. Misery loves company.

tcichon

do you own a Mazda6? Are you a salesman? You seem to know allot about the avenues to take with all the other Mazda 6 owners. I am a very busy person,like everyone else on this website. I was shocked my new Mazda broke down. I bought this car because I was having problems with my other car. I wanted a dependable car..The only thing I wanted to knoww was if this has happened to anyone else. I KNOW IT WOULD HAVE BEEN WORSE IF THE CAR DID NOT SHUT DOWN. I AM NOT STUPID!!!!!!!

lmp180psu

tcichon doesn't like group hugs Whatever happened to the civil talk about rust

mazda6s

I was just trying to explain what I meant so you would know I wasn't being rude. I didn't mean to imply that you are stupid either.

aromas

Man it's getting hot in here! How about a joke everyone?

Q. Why did the Mazda 6 cross the road?

A. To get to the body shop! (HAHAHAHOHOHOHAHA)

You wanted rust talk didn't you. Trust me it sounds alot funnier if you drink a few beers. Then again I find my rust funny after a few beers as well.

mazda6s

Are you within the official Mazda VIN range for the "staining" fix? Is yours 03 or 04?