2024 MAZDA CX-90 Electrical System Problems

The hybrid system malfunction, does not allow the car to start. This stranded us with children [XXX] in the car. This is the second time this has happened. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I am reporting an unresolved safety-related defect with my Mazda CX-90. The vehicle began experiencing repeated malfunctions affecting reliable operation while being driven. The issue was reported to the dealer while the vehicle was still under the manufacturer’s original warranty. The vehicle was taken to a Mazda dealership for diagnosis and repair. The problem has not been resolved, and the vehicle has been held at the dealer for over 30 days. I was provided a manufacturer loaner vehicle because my vehicle has not been deemed reliable to return to service. Mazda North America has escalated the issue and informed the dealer that they are “waiting on Japan” for engineering guidance, indicating there is currently no approved repair or resolution. As of now, no permanent fix has been identified. This defect raises safety concerns because the vehicle’s reliability cannot be assured, and returning the vehicle to service without a confirmed repair could put occupants and others at risk. The extended out-of-service time and lack of an approved repair suggest a potential systemic issue. The vehicle remains available for inspection and is currently in the possession of the Mazda dealer. -

My new Mazda CX-90 failed to restart after being stopped at a stop sign. After restarting manually, the dash displayed the check engine light and the “i-stop malfunction” light. The car now flashes this warning whenever it is on. There is an open recall for this issue (24V-816) but my local Mazda dealer does not pull anything up when they search my VIN. It appears the recall only applies to these vehicles built between 12/23 and 4/24. My car was built in 11/23. I believe this recall should be expanded to included more vehicles like mine.

I am reporting serious safety concerns with my Mazda CX-90 PHEV (leased, manufactured September 2023). These issues create unacceptable risk to occupants and other road users. Multiple Severe Recalls: My vehicle has had at least four major recalls: • 6323J – Engine & Motor Shutdown: Complete loss of propulsion without warning. • 7024J – ECU Software Failures: Loss of drive power and restart failures. • 24V817000 – EV Mode Power Loss: Sudden propulsion loss in EV mode. • 6724E – Sudden Braking: Automatic braking without cause. These defects could lead to crashes or fatalities. Hybrid System Malfunctions: Two recent “Hybrid System Malfunction” warnings required dealer visits. These failures could cause the car to shut off while driving—even at highway speeds. • First incident: Battery-related issue. • Second incident: Triggered by a loud noise during startup, impacting the AVAS system. A loud noise should never disable a family vehicle, indicating a design flaw. Charging Safety Issues: Charging via a standard outlet caused flickering lights and breaker buzzing in my house. A licensed electrician diagnosed harmonic distortion from the onboard charger. I spent $7,500 on electrical upgrades (dedicated EV line and panel upgrade) to charge safely. Manufacturer Response: I have had an open case with Mazda corporate for nearly two weeks. They refuse to acknowledge overall vehicle safety or provide written documentation confirming safety. Request: I urge NHTSA to investigate whether these defects represent a systemic safety issue in Mazda CX-90 PHEV models and take appropriate regulatory action

The contact owns a 2024 Mazda CX-90. The contact received notification of NHTSA Campaign Number: 25V568000 (Electrical System); however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure.

"The steering wheel intermittently sticks and feels resistant when switching lanes or making turns, especially at highway speeds. It does not return smoothly to center, making it feel unsafe and unpredictable. I brought the vehicle to the Mazda dealership, but they stated they 'cannot replicate the issue' and refused to perform any repairs. This is a safety concern because the sticky steering can make it difficult to control the vehicle and could potentially lead to a crash. There are no warning lights or error messages displayed when this occurs. The issue happens intermittently, making it hard to demonstrate on demand, but it is recurring and worsening. Since this is a brand-new 2024 Mazda CX-90, I believe this could indicate a defect in the electric power steering system or related components."

Brought vehicle into Dealer for Service due to Check Engine Light being on and Notification of a Malfunction of the I-Stop System. Service Tech indicates that this is a known issue with the Hybrid Battery in these vehicles that could cause the vehicle to unexpectedly stall. This safety issue is significant enough that they would not let us take our car home while we wait for them to obtain a battery, which are currently on backorder. Pursuant to a conversation with a Mazda Customer Experience Representative this has been a known issue since at least January. We have not received any correspondence from Mazda regarding this issue. It would appear that a Bulletin or Recall is warranted for what appears to be a prevalent issue with significant safety impacts.

The contact owns a 2024 Mazda CX-90. The contact received notifications of NHTSA Campaign Numbers: 24V814000 (Electrical System, Structure) and 24V815000 (Power Train, Engine and Engine Cooling); and parts were available. The contact stated that upon taking the vehicle to the dealer, he was informed that the manufacturer would not cover the cost of the repair. The manufacturer was made aware of the issue and confirmed with the contact that as the second owner of the vehicle, he was not entitled to have the cost of the repair covered by the manufacturer. The contact had not experienced a failure. Parts distribution disconnect.

Hybrid battery failure. Battery issue can cause car to lock up while driving. Dealer service department indicate they have at least 6 vehicles with this same issue. The vehicle has not been inspected by other than the dealership service department that I am aware of. While driving to the dealership for a routine oil change, the car made a quick odd noise then 3 alerts came on said Hybrid system malfunction have vehicle inspected, engine malfunction, system malfunction. Dealer inspected vehicle determined needed a hybrid batter replacement, indicated they could not say vehicle was safe to drive as it could just stop working. Considering they already have a number of cars with same issues in the shop I am concerned this could be a defect problem in many vehicles.

Bought this brand new CX90 Premium in October 2024! As of today Feb 11, the car has been in the dealership 4 x fir the same issue!! Dead battery after sitting for 2 weeks! They have replace one small battery and that worked for a month! Took it in last week for the same issue! Dead battery! We find that this is a very coming problem. They said they would now replace the 58 volt battery but it is on back order for 8 weeks. In the mean time I’m paying on this car and I have to drive a loaner which isn’t even close to my car! I’m finding out by talking to other customers this is a common problem! We didn’t get any notice or call! I am demanding this be considered “lemon law” as this is the fourth time it has been in for the same problem. I want all my money back that I paid and demand Mazda USA issue recalls for this issue. It is definitely a big safety issue! The dealer seems to be trying but they are frustrated as well! They are Olympia Mazda in Olympia, Wash, service manager is James Ellis Please respond! Thank you for any help and assistance [XXX] and [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The fuel gauge and range indicator are faulty. I was doing long-distance highway driving during the holidays. At 1/4 tank, the range indicator said 110 miles until empty. As soon as the needle dipped a fraction below 1/4 tank (about 20 miles later) the range indicator dropped instantly to 40 miles left AND THEN DROPPED ONE MILE PER SECOND UNTIL IT REGISTERED ZERO. The needle also fell at the same rate until I was driving on the interstate with zero range and a gas gauge buried below empty. All of this occurred within one minute. I pulled into the nearest gas station and filled up with 12.71 gallons (it's an 18.5 gallon tank). So I actually had 5.79 gallons left (or 156.33 miles of range at 27mpg on the highway). Not being able to rely on the gas gauge/range indicator is a safety issue.

Stopped at a red light on a busy 2-lane road. I-stop function turned the engine off. When the light turned green, releasing the brake caused a "Hybrid Battery Malfunction" error and the engine failed to start. We put the transmission in park and attempted to turn off and turn on the car with the push to start button. When we attempted to start the car with the push to start button, the car would not start. We were unable to shift into neutral to move the car out of the busy 2-lane highway and were blocking traffic for about an hour. The first tow truck to arrive was unable to move the car onto the flat-bed because the transmission was stuck in park and would not go into neutral so another tow truck was dispatched with a dolly. Our safety was at risk because we were stuck in an immobile car in busy highway traffic. A police officer arrived to help direct traffic around our disabled car. The vehicle is currently at the dealership and has not been inspected as of the time of this report.

On July 15, 2024 this vehicle at 50 mph on cruise control suddenly flashed white warning words indicating problems with the cruise control and immediately thereafter started flashing “hybrid malfunction” and to return to service dealer. At the time of the hybrid malfunction warning which was right after the quick cruise control warning, the engine operation, specifically the gas pedal no longer delivered power to vehicle, either electric or gas. Additional warning was to pull off to the side and stop and turn off vehicle. This occurred and vehicle was pulled to the side put into park and turned off. Waited approximately 3 to 5 minutes and restarted the engine which started in gas with no electric although there was electrical charge on the battery. Was able to continue to our final destination approximately 15 minutes later and no more than 10 miles driven. Hybrid malfunction was still visible on the dash to include the warning stating that vehicle needed to go to the service department. Approximately an hour later, vehicle was turned on again with the same warning about the hybrid malfunction, however, engine started in electric. Drove vehicle to dealership and stated what happened. Dealership the next day stated that this was a phantom code known by Mazda, but no problems associated with the code. Vehicle picked up per service advisors request two days later. Mazda dealership stated that headquarters had eyes on this particular vehicle. A day later after the pick up Mazda dealership requested vehicle be brought back for a “DC box” repair. Dealership stated this process would take a week or thereabouts to replace this component. Vehicle currently in dealership service.

There has been two dangerous failures both occurring in an intersection. First instance was in December of 2023 whey the fuel pump failed while turning in an intersection. The second incident was a hybrid battery malfunction, rendering my vehicle unusable in the middle of an intersection again. This was 03/2023

The major issue that happened to our newly purchased CX 90 last February 3 with more than 500 miles on it started around 5:30 pm of February 8, while my wife is driving this vehicle with my daughter, all of a sudden the car stopped at the middle of the road with warning signs popping up in the dash screen like I-active sense malfunction, hybrid battery malfunction, engine malfunction light on, and on top of these, critical vehicle malfunction. The car won't start and disabled. Also, the vehicle cannot switch to neutral gear to push/pull the vehicle to the side that made the vehicle blocking the roadway until the tow truck came in. My wife and daughter's life was put in danger when this vehicle suddenly stopped in the middle of the road with cars passing by on both ways. I also found out based on the NHTSA vehicle safety, Mazda recall website, carfax and Kelly blue book, that this particular vehicle with its VIN has a SAFETY RECALL due to its steering issue that may increase risk for crash. This was not disclosed to us when we are on the process purchasing this vehicle and they did state inspection and passed it that made we doubt how did it happened.. The vehicle is now with the dealership repair shop and the last update I receive was the technician is still checking on it.

On 02/07/2024, malfunction prompts displayed on my dash relating to I-stop functionality, hybrid functionality, engine. Took the vehicle the next day to be diagnosed, the appointment was set as an inspection with oil change, filter change, and the prompts on my dash. I was advised that the issue to the prompts stemmed from the hybrid battery. I was told that contact was made to the manufacturer and that the battery would have to be replaced. The battery is on backlog and it would be about a month to arrive. I called in after leaving with additional questions as to the safety of the vehicle with the hybrid battery problem. The man on the phone said it is safe to drive, what would be affected would be the mileage I would not get because the hybrid portion was not functioning. He mentioned that a separate case was created with another 2024 cx-9 car owner with the same hybrid battery issue. It’s now two known cases with the hybrid battery issue. I called customer service and was provided with case number 00174049. The resolution to that call to corporate customer service is that I would receive a call back from the local dealership about a loaner car with about an hour. I became aware of a fourth recall, that the corporate agent referred to as a campaign, pertaining to the steering wheel. I asked my dealership advisor if that can be looked in addition to the other issues. She stated that she could not because it has not been launched. The corporate agent advised me that notification would normally happen 2-3 weeks. I looked up the steering wheel recall on the dep of transportation website. The recall has been published since the 18 of Jan 2024 and have yet to receive notification. I only found out today when I took the vehicle in for inspection.

The contact owns a 2024 Mazda. CX-90 The contact stated while driving at undisclosed speeds, the blind side detector inadvertently illuminated. The contact stated that the blind side detector randomly illuminated without an object being nearby. The vehicle was taken to the dealer where it was diagnosed that the blind spot sensors failed and needed to be replaced. The vehicle was repaired; however, the failure recurred. The vehicle was taken back to the dealer, but the failure could not be duplicated. The vehicle was not repaired. The manufacturer was notified of the failure and the contact was provided a case number. The failure mileage was approximately 1,300.

Mileage: 13,000

During normal driving conditions going down a state highway, the vehicle lost speed with adaptive cruise control enabled. Noticing the vehicle was losing speed, I depressed the accelerator pedal. The accelerator pedal was unresponsive and unable to accelerate, I had to maneuver off the highway. Luckily, the car behind my vehicle was far enough behind me and my vehicle was going fast enough that I was able to coast to a safe stop on the side of the highway. A message popped up on the instrument cluster screen informing me to shift the transmission to Park in order to use the accelerator pedal. If this had happened on a road with little to no shoulder, the vehicle would have come to a sudden stop with nowhere to maneuver to. This would have created a dangerous situation for me, and any vehicle directly behind me. I then parked the vehicle on the side of the highway and with the vehicle still on and engine running, I again tried depressing the accelerator pedal. Again, there was no response from the pedal. I then turned the vehicle off, and restarted the vehicle. I was finally able to use the accelerator pedal and returned to the highway and my drive. The dealership was contacted a few hours after the incident, and the vehicle has yet to be inspected or problem reproduced. The vehicle is a 2024 MY and has been owned for only one month. Unfortunately, this incident is only one of five total electrical issues I have had with this vehicle. This was the most important issue to report because it involved my own safety.