2011 MAZDA MAZDA6 Structure Problems

The front and back cross members underneath my Mazda6 have completely rusted out. There are numerous complaints about Mazda's "Safety Recall 2818I Expansion" not covering the back support member and also not considering Nebraska to be a Salt Belt state despite the state, and specifically Omaha using salt to treat their roads in the winter. On [XXX], my front cross member completely failed due to rust, causing my vehicle to lose control. I've taken my car to the mechanic and they confirmed the front and back cross members are completely rusted and need replacement costing $7,000. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2011 Mazda Mazda6. The contact stated that while her mother was driving at slow speeds in a parking area, there was an abnormally loud metallic sound coming from underneath the vehicle, and moments later, the vehicle became extremely difficult to maneuver. No warning lights were illuminated. The vehicle was towed to the dealer, who determined that the rear crossmember had detached from the vehicle due to excessive corrosion of the subframe. The contact was informed that the vehicle could not be repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 19V323000 (Structure, Suspension); the VIN was previously included, but was repaired in 2019. The contact stated that the recall repair was for the front passenger’s side lower control arm. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 150,000.

Mileage: 150,000

The contact owns a 2011 Mazda Mazda6. The contact stated that while the vehicle was at the dealer for routine service, the vehicle was diagnosed with rust and corrosion of the sub-frame. The contact was informed that the sub-frame needed to be replaced. The vehicle was not repaired. The contact was informed of NHTSA Campaign Number: 19V323000 (Structure, Suspension); however, the VIN was not included in the recall. The manufacturer was made aware of the failure. The contact was advised to contact the NTSA Hotline to report the failure. The failure mileage was approximately 100,000.

Mileage: 100,000

After getting the recall information about the front crossmember rusting out due to corrosion, I decided to check the rear crossmember on my car. WOW, the rear crossmember is SO much worse than the front one and I’ve read hundreds of similar stories about the exact same thing happening to other Mazda 6 sedans around these model years (2009-2013). The rear crossmember on my car, which supports the entire rear suspension is completely rusted thru in several spots and the lower end links aren’t even attached anymore because the brackets literally fell off and so now both back tires are leaning in at the top. It is very noticeable! Very unsafe to drive! I decided to park this car until a solution is reached with Mazda or the NHTSA on how to deal with this. I don’t know why the front crossmember was recalled but not the rear? There’s only 2 things that are rusted on my car, period…the front & rear crossmembers!

The contact owns a 2011 Mazda Mazda6. The contact stated that while the independent mechanic was performing an oil change on the vehicle, the independent mechanic informed the contact that the rear subframe was severely rusted with holes in the subframe. The vehicle was taken to the dealer, where it was determined that the rear subframe needed to be replaced. The vehicle was not repaired. The contact stated that the vehicle was previously repaired under NHTSA Campaign Number: 19V323000 (Structure, Suspension). The manufacturer was notified of the failure and informed the contact that the VIN was not included in the recall. The failure mileage was approximately 129,000.

Mileage: 129,000

The contact's daughter owns a 2011 Mazda Mazda6. The contact stated that while her daughter was driving at an undisclosed speed, the steering wheel inadvertently moved to the left at a 30–35-degree angle. Additionally, the rear end of the vehicle swayed while coming to a stop. The vehicle was taken to an independent mechanic, who determined that the crossmember was severely corroded and the front driver's side crossmember had cracked. The vehicle was then towed to the dealer, where it was diagnosed that the front sub frame, sub frame link, sway bar, sub frame nuts, and bolts needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was opened. The contact related the failure to NHTSA Campaign Number: 19V323000 (Structure, Suspension); however, the VIN was not included in the recall. The failure mileage was approximately 89,000.

Mileage: 89,000

The rear cross member/subframe is completely rusted in two and the rear lower forward control arm is detached from cross member/subframe on both sides. There is currently an active recall for the front cross member due to accelerated corrosion from road salt but I’m not aware of any inclusion of the rear frame or suspension components tied in with this recall. It definitely needs added to it as this is VERY dangerous, possibly even more so than the front. Rest of the actual car body is fine, except for a little bit of surface rust. Please add this to the current corrosion recall! Car is registered in WV and is available for inspection anytime and I will be attaching pictures and I also have a video but it won’t let me post it on here.

I purchased a used vehicle in NH from a private seller "as is", repaired tires and brakes, passed MA state inspection and dropped the car off to address the recall, which I had researched via a VIN number search. The dealership informed me that the body had corroded beyond repair, and they cannot perform the required repair for the recall. While the dealership has been helpful, this looks like a major underlying manufacturing flaw for a vehicle at 115K built in 2011.

Corrosion on the rear subframe as a result of salt on roadways used to clear snow

Rear cross subframe is very rotten and my mechanic told me not safe to drive car. Mazda had recall on front but not on rear. Is made of same material I look at line and a lot of people have same problem I hope you can help us with this problem Thank you and I hope you can investigate this major issue

THE REAR SUBFRAME HAS EXCESSIVE RUST AND MECHANIC REPORTED IT WOULD NOT PASS YEARLY INSPECTION UNLESS REPLACED. FRONT SUBFRAME HAD THE SAME PROBLEM IN 2019 AND WAS REPLACED THROUGH MAZDA RECALL. MECHANIC REPORTS THE REAR SUBFRAME HAS THE SAME EXACT NATURE OF RUST.

Mileage: 121,549

TL* THE CONTACT OWNS A 2011 MAZDA MAZDA6. THE CONTACT STATED THE VEHICLE FAILED THE STATE INSPECTION DUE TO CORROSION. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER NORTH PENN MAZDA (181 BETHLEHEM PIKE, COLMAR, PA 18915, (267)956-1160) WHERE IT WAS DIAGNOSED WITH NEEDING THE UNDERBODY TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED AS OF YET. UPON INVESTIGATION, THE CONTACT ASSOCIATED THE FAILURE WITH NHTSA CAMPAIGN NUMBER: 19V323000 (STRUCTURE, SUSPENSION) HOWEVER, THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS INFORMED OF THE FAILURE AND INFORMED THE CONTACT THAT THEY WERE UNABLE TO PROVIDE ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 88,259.

Mileage: 88,259

THE VEHICLE STARTED TO PRODUCE TIRE SCREECHING UNDER NORMAL DRIVING CONDITIONS AND APPEARED TO BE OUT OF ALIGNMENT WITH THE STEERING WHEEL TO THE LEFT WHILE DRIVING STRAIGHT. WITHIN A FEW MILES, IT BECAME DIFFICULT TO CONTROL, AND THEN THE DYNAMIC STABILITY CONTROL OFF AND TRACTION LOSS LIGHTS CAME ON. UPON INSPECTION AT AN AUTO REPAIR SHOP, THE RIGHT FRONT SIDE OF THE FRAME HAD SEVERELY RUSTED. I WAS ADVISED THAT IT WAS UNSAFE TO DRIVE. THERE WAS NO OTHER RUST OR DAMAGE ON THE VEHICLE.

Mileage: 120,000

I WAS IN A CRASH WHERE MY FRONT END WAS EASILY DAMAGED AND PASSENGER AIR BAGS NOT DEPLOYED

TL* THE CONTACT OWNS A 2011 MAZDA 6. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 19V323000 (STRUCTURE, SUSPENSION); HOWEVER, THE PARTS TO DO THE REPAIR WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. EICH MAZDA (1933 W DIVISION ST, ST CLOUD, MN 56301, (320) 251-1737) WAS CONTACTED AND CONFIRMED THAT THE PARTS WERE NOT AVAILABLE FOR THE RECALL REMEDY. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.

TL* THE CONTACT OWNS A 2011 MAZDA 6. THE CONTACT STATED THAT THE FRAME WAS RUSTED AND THE ENTIRE VEHICLE WAS CORRODED. THE VEHICLE WAS DRIVEN TO MAZDA MALL OF GEORGIA (3546 GA-20, BUFORD, GA 30519, (678) 394-3085) WHERE IT WAS DIAGNOSED THAT A NEW FRAME NEEDED TO BE INSTALLED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND DID NOT ASSIST. THE FAILURE MILEAGE WAS 89,914.

Mileage: 89,914

FRONT SUSPENSION SUBFRAME IS COMPLETELY RUSTED DISABLING THE VEHICLE AND MAKING IT UNSAFE FOR OPERATION. COMPLETE SUBFRAME WILL NEED TO BE REPLACED DUE TO THE SEVERITY OF RUST AND CORROSION BEFORE VEHICLE CAN BE OPERATIONAL AGAIN.

Mileage: 154,000

THE RIGHT SIDE OF THE ENGINE CRADLE ROTTED AWAY, CAUSING THE RIGHT LOWER CONTROL ARM TO BREAK AWAY AND LOOSING CONTROL OF THE VEHICLE. I WAS ONLY GOING APPROX. 15 MPH ON A SIDE STREET AND APPLYING THE BRAKES WHEN THIS ACCORDED. THE VEHICLE ONLY HAVE APPROX. 85K MILES ON IT.

Mileage: 85,000

WHILE DRIVING ON THE HIGHWAY AT ABOUT 55 MPH I HEARD A LOUD NOICE AND THE CAR SUDDENLY STARTED TO SWERVE, THE STEERING BECAME DIFFICULT. I WAS ABLE TO SLOW DOWN AND PULL OFF THE HIGHWAY AND TO A PARKING LOT. DURING THE RIDE AT A MUCH SLOWER SPEED AROUND 20-25 VERY LOUD NOISES CAME FROM THE RIGHT FRONT OF THE CAR ESPECIALLY,WHEN THE THE WHEEL WAS TURNED. THE VEHICLE IS NOT DRIVABLE AND HAD TO BE TOWED. THE SUB FRAME RUSTED OUT AND THE LOWER CONTROL ARM PUSHED THE RIGHT FRONT TIRE INTO THE BACK OF THE WHEEL WELL.

Mileage: 188,805

RECENTLY WHILE DRIVING DOWN A STRAIGHT ROAD ABOUT 35 MPH MY STEERING STARTED TO FAIL IN ORDER TO KEEP THE CAR GOING STRAIGHT THE WHEEL HAS TO BE TURNED TO THE LEFT AND HELD IN PLACE. THE INDICATOR LIGHTS CAME ON THAT MY BRAKE ASSIST SYSTEM IS OFF/FAILING. THE CAR SLIGHTLY JERKS TO THE RIGHT WHEN TRYING TO STAY GOING STRAIGHT. THERE WAS NOISE COMING FROM UNDER THE CAR WHEN TURNING AND GOING IN REVERSE. UPON INSPECTION FOR THE BODY SHOP THE SUBFRAME IS PREMATURELY ROTTING AND THAT IS WHY I LOST PROPER STEERING ALONG WHY THE OTHER ISSUES OCCURRED TOO. THE CAR IS INOPERABLE AND THE SUBFRAME IS NOT HOLDING AS IT SHOULD

Mileage: 100,700

I AM WRITING THIS LETTER BECAUSE I RECENTLY LEARNED ABOUT A SAFETY ISSUE WITH MY CAR DURING A ROUTINE OIL CHANGE ON THURSDAY, JULY 19, 2018. I WAS MADE AWARE BY THE MECHANIC THAT THE SUBFRAME ON MY 2011 MAZDA6 IS COVERED IN RUST AND SHOULD BE REPLACED. UPON TRUSTED INSPECTIONS FROM TWO DIFFERENT AUTO SHOPS, THE RESULT IS THE SAME: I NEED A NEW SUBFRAME BECAUSE IT IS EXTREMELY DANGEROUS IF IT BROKE AWAY. I BOUGHT MY CAR NEW IN 2011, SO I AM SHOCKED THAT A MAJOR STRUCTURAL COMPONENT OF MY CAR IS NOW COMPROMISED, PUTTING MY SAFETY AT RISK. THE SUBFRAME IS ON NATIONWIDE BACK ORDER, WHICH TELLS ME (AND BOTH MECHANICS ECHOED EACH OTHER) THAT THIS IS A MUCH BIGGER PROBLEM. MY DAILY COMMUTE TO MY JOB HAS ME DRIVING ON THE INTERSTATE, AT 70 MPH, AT A TOTAL OF APPROXIMATELY 80 MILES PER DAY. I NO LONGER FEEL SAFE WHEN DRIVING MY CAR. I DID SOME ONLINE RESEARCH AND DISCOVERED MAZDA HAD OVER 20 REPORTS FROM OWNERS WHO SAY RUST IN THEIR 2009-2010 MAZDA 6S HAS CAUSED, OR NEARLY CAUSED, A STEERING FAILURE. THIS EXTENDED EVEN FURTHER INTO OTHER MODEL MODELS FOR SUBFRAME ROT DEEMED DANGEROUS. IN 2016, MAZDA HAD TO RECALL 190,000 CX-7S FOR A SIMILAR ISSUE WHEREIN CORROSION WAS CAUSING SUSPENSION FAILURE. DAYS LATER, 2.2 MILLION MAZDAS WERE RECALLED WORLDWIDE. I CALLED MAZDA'S CUSTOMER SERVICE, BUT THEY DECLINED TO HELP ME BECAUSE 'I DIDN'T CONTINUE MY RELATIONSHIP WITH MAZDA", AFTER MY WARRANTY WAS UP. HOWEVER, WHILE UNDER WARRANTY, I ONLY TOOK MY CAR TO MAZDA FOR SERVICE BECAUSE I KNEW I HAD TO DUE TO THE WARRANTY, DESPITE THEIR COMPLETE INCOMPETENCE. DURING THE TIME MY CAR WAS UNDER WARRANTY AND WAS SERVICED AT MAZDA, THEY INSTALLED MY DRIVER'S WINDSHIELD WIPER BACKWARDS. IT POPPED OFF THE NEXT DAY DURING A DOWNPOUR. TWO TIMES THEY DIDN'T CLOSE MY HOOD FULLY (ONCE LEFT OIL CAP ON TOP OF MY ENGINE). FOR THESE REASONS, I SOUGHT OUT A MORE RELIABLE MECHANIC AFTER WARRANTY.

CURRENTLY, I HAVE BEEN WAITING FOR A REPLACEMENT DASHBOARD FOR THE LAST TWO YEARS. THE RIGHT SIDE OF MY DASH BOARD IS MELTED. APPARENTLY IT IS A FACTORY DEFECT IN MY MODEL CAR. TWO YEARS AGO THE DEALERSHIP TOOK PICTURES, SENT IN THE CLAIM, AND I STARTED WAITING. SINCE THEN I HAVE RECEIVED AT LEAST TWO LETTERS TO UPDATE ME TO THE FACT THAT THE PART STILL IS NOT AVAILABLE. SO I CONTINUE TO DRIVE AROUND WITH A MELTED DASH BOARD, WHICH BY THE WAY IS A STICKY MESS. NOW, AS IF TO ADD INSULT TO INJURY, I HAVE RECEIVED A NOTICE THAT MY PASSENGER AIR BAG INFLATOR NEEDS TO BE REPLACED. YET AGAIN, THE PART IS UNAVAILABLE AND I WILL SOMEDAY RECEIVE NOTIFICATION WHEN THE PART IS AVAILABLE. EVEN MORE OUTRAGEOUS IS THAT THE LETTER SAYS, "UNTIL THIS REPAIR IS PERFORMED, DO NOT ALLOW PASSENGERS TO RIDE IN THE FRONT PASSENGER SEAT. IT HAS BEEN MONTHS AND STILL NO LETTER CONCERNING THE PART BEING CORRECTED.

THE DASH OF MY CAR IS MELTING - A KNOWN PROBLEM IN THE MAZDA 2011, AS WELL AS OTHER MAKES AND MODELS, THAT IS EXACERBATED BY THE HEAT. I LEAVE IN SOUTH CENTRAL TEXAS, WHERE WE SEE A LOT OF HEAT. I CALLED OUR MAZDA DEALERSHIP TO ASK WHAT COULD BE DONE ABOUT IT. THEY SAID TO JUST WAIT UNTIL MAZDA ISSUES A RECALL. IN ADDITION, THEY SAID THEY HAVE HAD THESE PARTS ON ORDER SINCE DECEMBER AND STILL HAVEN'T GOTTEN THEM IN. A RECALL NEEDS TO BE ISSUED AND REPAIRS NEED TO BE MADE. THE DASH BECOMES STICKY AND SHINY, WHICH IN TURN REFLECTS LIGHT UP ON TO THE WINDSHIELD. VISIBILITY IS THEN CUT DRASTICALLY TRYING TO SEE THROUGH THE REFLECTION FROM THE DASH.

TAKATA RECALL - 2011 MAZDA 6 I WAS THE PASSENGER IN A COLLISION IN NOVEMBER 2015 WHERE THE 2011 MAZDA 6 WAS T-BONED ON THE DRIVER'S SIDE BY ANOTHER VEHICLE (FORD FUSION), WHICH MADE THE MAZDA 6 SPIN SEVERAL TIMES, HOP A CURB, AND DEPLOY THE AIRBAGS. AS THE PASSENGER (FRONT SEAT) I SUFFERED INJURIES CAUSED BY THE TAKATA AIRBAGS AND REQUIRED GOING TO THE HOSPITAL FOLLOWING THE COLLISION. INJURIES INCLUDED AT LEAST THREE FRACTURED/BROKEN RIBS AND MAJOR BRUISING ON MY RIGHT KNEE. INJURIES TOOK OVER 6 MONTHS TO HEAL, TAKING HEAVY DOSES OF PAIN KILLERS JUST TO MANAGE THE PAIN. LINGERING EFFECTS FROM THIS COLLISION CAN STILL BE FELT 7 MONTHS LATER. THE DRIVER DID NOT SUSTAIN MAJOR INJURIES ASIDE FROM SCRAPES AND A FEW BRUISES. POLICE REPORTS DETERMINED THAT THE DRIVER OF THE FORD FUSION WAS RESPONSIBLE FOR THE COLLISION AND WAS CHARGED WITH CARELESS/RECKLESS DRIVING. THAT DRIVER FAILED TO STOP/YIELD IN THEIR TURNING LANE BEFORE DRIVING STRAIGHT INTO THE MAZDA 6. THE MAZDA 6 WAS DECLARED TOTALED BY INSURANCE. THE MAZDA 6 WAS ADDED TO THE TAKATA AIRBAG RECALL IN MAY 2016, APPROXIMATELY 6 MONTHS AFTER THE ACCIDENT HAD OCCURRED.

SUNGLASS HOLDER ABOVE REAR VIEW MIRROR POPS OUT WHILE DRIVING OBSTRUCTING THE DRIVERS USE OF REAR VIEW MIRROR. *TR

Mileage: 41,000