TSB for Mazdas
#1
08-20-2009, 05:29 PM
TSB for Mazdas
I have at my disposal a resourse that lets me look up specs, problems, and other things for ANY car, i have NO idea how to clean this up or organize it to make it easier to find possible TSB's for your car ill do my best.
2000-2006 MULTI-MODEL - BODY VIBRATION OR STEERING WHEEL SHIMMY
Note : This bulletin supersedes the following TSB(s): 02-001/03. Please update your records accordingly.
BULLETIN NOTE This bulletin supersedes the previous bulletin 02-001/03, issued on 02/24/03.
The APPLICABLE
MODEL(S)/VINS and DESCRIPTION have been revised.
APPLICABLE MODEL(S)/VINS
2000-2003 Protege
2002-2003 Protege5
2000-2002 626
2000-2002 Millenia
2000-2006 Miata
2004-2006 RX-8
2004-2006 Mazda3
2006 Mazda5
2003-2006 Mazda6
2000-2006 MPV
2001-2006 Tribute
2000-2006 B-Series Truck
DESCRIPTION
If a vehicle has body vibration or steering wheel shimmy while driving, and the root cause is determined to be tire balance, re-balance the tires using a Hunter GSP 9700/9712 balance machine. When using the Hunter GSP 9700/9712, be sure to use the following centering cones and cone/wheel set up listed below.
Using the appropriate centering cone ensures that the wheel will be properly centered to the centering cone.
To find the location of a GSP 9700/9712 near your dealer, visit Hunter's web site at www.gsp9700.com and click on "Find a GSP9700 Near You".
2000-2006 MULTI-MODEL - BODY VIBRATION OR STEERING WHEEL SHIMMY
Note : This bulletin supersedes the following TSB(s): 02-001/03. Please update your records accordingly.
BULLETIN NOTE This bulletin supersedes the previous bulletin 02-001/03, issued on 02/24/03.
The APPLICABLE
MODEL(S)/VINS and DESCRIPTION have been revised.
APPLICABLE MODEL(S)/VINS
2000-2003 Protege
2002-2003 Protege5
2000-2002 626
2000-2002 Millenia
2000-2006 Miata
2004-2006 RX-8
2004-2006 Mazda3
2006 Mazda5
2003-2006 Mazda6
2000-2006 MPV
2001-2006 Tribute
2000-2006 B-Series Truck
DESCRIPTION
If a vehicle has body vibration or steering wheel shimmy while driving, and the root cause is determined to be tire balance, re-balance the tires using a Hunter GSP 9700/9712 balance machine. When using the Hunter GSP 9700/9712, be sure to use the following centering cones and cone/wheel set up listed below.
Using the appropriate centering cone ensures that the wheel will be properly centered to the centering cone.
To find the location of a GSP 9700/9712 near your dealer, visit Hunter's web site at www.gsp9700.com and click on "Find a GSP9700 Near You".
#2
08-20-2009, 05:31 PM
09-015/05 2004-2006 MAZDA3 - SNAP OR CLUNK NOISE FROM FRONT POWER WINDOWS
APPLICABLE MODEL(S)/VINs
2004-) 2006 Mazda3 with VINs lower than JM1BK****61401679 (produced before July 6, 2005) equipped with Power Windows
DESCRIPTION
Some customers may complain of a loud snap or clunk noise when operating the front power windows. The noise is most likely to occur when the window is lowered halfway and is then raised. The noise will not occur more than once each time this operation is attempted on a window.
This noise is due to insufficient torque on the screws that hold the window carrier plate to the window regulator.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify concern on the applicable power window.
2. Lower the affected window to where the top of the glass is 60 mm (2.4 in) above the top of the interior door trim.
3. Record customer's pre-set radio stations.
4. Disconnect the negative battery cable.
5. Remove the inner garnish according to Workshop Manual (section 09-17 INNER GARNISH REMOVAL/INSTALLATION).
6. Remove the front door trim according to Workshop Manual (section 09-17 FRONT DOOR TRIM REMOVAL/INSTALLATION).
7. Remove the two hole covers found in the center area of the front door unit just below the door wire harness.
CAUTION: The screws thread into plastic inserts, do not over torque them.
8. Tighten the window regulator / carrier plate screws to a torque of 4.0 Nm (35 in-lbs).
9. Reassemble the interior door trim and garnish in reverse order.
10. Reset customer's pre-set radio stations.
11. Verify repair.
APPLICABLE MODEL(S)/VINs
2004-) 2006 Mazda3 with VINs lower than JM1BK****61401679 (produced before July 6, 2005) equipped with Power Windows
DESCRIPTION
Some customers may complain of a loud snap or clunk noise when operating the front power windows. The noise is most likely to occur when the window is lowered halfway and is then raised. The noise will not occur more than once each time this operation is attempted on a window.
This noise is due to insufficient torque on the screws that hold the window carrier plate to the window regulator.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify concern on the applicable power window.
2. Lower the affected window to where the top of the glass is 60 mm (2.4 in) above the top of the interior door trim.
3. Record customer's pre-set radio stations.
4. Disconnect the negative battery cable.
5. Remove the inner garnish according to Workshop Manual (section 09-17 INNER GARNISH REMOVAL/INSTALLATION).
6. Remove the front door trim according to Workshop Manual (section 09-17 FRONT DOOR TRIM REMOVAL/INSTALLATION).
7. Remove the two hole covers found in the center area of the front door unit just below the door wire harness.
CAUTION: The screws thread into plastic inserts, do not over torque them.
8. Tighten the window regulator / carrier plate screws to a torque of 4.0 Nm (35 in-lbs).
9. Reassemble the interior door trim and garnish in reverse order.
10. Reset customer's pre-set radio stations.
11. Verify repair.
#3
08-20-2009, 05:34 PM
2004-2006 MAZDA3
SQUEAKING NOISE FROM FRONT SUSPENSION WHEN
PASSING OVER A BUMP
APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 vehicles with VINs lower than JM1 BK**** ** 483440 (produced before January 27, 2006)
DESCRIPTION
Some vehicles may exhibit a squeaking noise from the front suspension when passing over a bump at a low speed. This is may be caused by one of the following.
The front lower arm making contact with the bushing, causing a squeaking noise.
The fluid in the rear bushing makes an unusual noise.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Replace front lower arm. Refer to appropriate Workshop Manual section 02-13 - FRONT LOWER ARM REMOVAL / INSTALLATION.
3. Perform toe-in inspection and adjustment. Refer to appropriate Workshop Manual section 02-11 - FRONT WHEEL ALIGNMENT
SQUEAKING NOISE FROM FRONT SUSPENSION WHEN
PASSING OVER A BUMP
APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 vehicles with VINs lower than JM1 BK**** ** 483440 (produced before January 27, 2006)
DESCRIPTION
Some vehicles may exhibit a squeaking noise from the front suspension when passing over a bump at a low speed. This is may be caused by one of the following.
The front lower arm making contact with the bushing, causing a squeaking noise.
The fluid in the rear bushing makes an unusual noise.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Replace front lower arm. Refer to appropriate Workshop Manual section 02-13 - FRONT LOWER ARM REMOVAL / INSTALLATION.
3. Perform toe-in inspection and adjustment. Refer to appropriate Workshop Manual section 02-11 - FRONT WHEEL ALIGNMENT
#4
08-20-2009, 05:36 PM
TSB: 09-012/06
2006 MAZDA3 - CLOCK INDICATION INCORRECT
APPLICABLE MODEL(S)/VINS
2006 Mazda3 with VINs lower than JM1 BK**** 61 473189 (Produced from July 1, 2005 to January 6, 2006)
DESCRIPTION
Some customers may complain that the clock runs slow or fast, and no matter how many times they have tried
to adjust the time, the clock display soon indicates the wrong time.
For the 2006 model year, the Information Display is what controls the clock, where in prior model years it was the audio unit that was the controlling component.
CLOCK RUNS FAST
It is possible that the customer has unintentionally performed the "Time Resetting Function", which will create
this symptom.
NOTE:
l The "Time Resetting Function" can create symptoms of the clock losing or
gaining time, even for vehicles that are outside of the listed VIN range. For
further details see TIME RESETTING FUNCTION.
When you encounter a customer complaint of an inaccurate clock where you suspect the "Time Resetting
Function" was performed, explain to the customer the time resetting function as described below and have
them continue to monitor the clock. (This function is also described in the owner¡Çs manual, "Interior
Equipment" section.)
CLOCK RUNS SLOW
Due to improper software, the clock may lose time when the ignition is turned to the ACC or OFF position.
NOTE:
l For vehicles that are outside of the listed VIN range that present this symptom,
refer to CLOCK RUNS FAST.
An updated Information Display has been introduced to address this concern. Customers having this concern
should have their information display replaced with an exchange unit as outlined in the repair procedure below.
NOTE:
l Do not remove the Information Display until the exchange unit is available and
in hand, because without the display, the driver cannot see the radio
information and climate control settings (on vehicles equipped with an
automatic climate control).
TIME RESETTING FUNCTION
While the clock is displayed with the ignition in the "ACC" or "ON" position, when the "SET" button ("INFO"
button for vehicles equipped with a TRIP COMPUTER) on the instrument panel is pressed for 1.5 seconds or
more then released, the time on the clock display is reset to the nearest hour and the minutes (and seconds)
are set to ZERO (00).
REPAIR PROCEDURE
NOTE:
l Do not remove the information display until the exchange unit is available and
in hand, because without the display, the driver cannot see the radio
information and climate control settings (on vehicles equipped with an
automatic climate control).
1. Verify customer clock concern.
2. Record radio presets.
3. Remove the center panel module. Refer to Workshop Manual section 09-20 CENTER PANEL
MODULE REMOVAL/INSTALLATION.
4. Replace the information display with a modified one. Refer to Workshop Manual section 09-20
CENTER PANEL MODULE DISASSEMBLY/ASSEMBLY.
NOTE:
l The modified part number was not changed from the original part, but all outgoing parts are to the latest modification level. Below is a
visual reference in identifying the level part equipped on a vehicle.
Modified Information Display will have a "9621" cast into the display
housing above the harness.
5. Reassemble in reverse order.
6. Reset radio presets and adjust the clock to the correct time.
7. Verify repair.
PART(S) INFORMATION
WARRANTY INFORMATION
NOTE:
l This warranty information applies only to verified customer complaints on
vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty
term information.
l Additional diagnostic time cannot be claimed for this repair.
l This part is subject to the UNITED RADIO exchange program. Claims submitted
where the Information Display was replaced without the use of an exchange
unit will be denied and/or debited.
2006 MAZDA3 - CLOCK INDICATION INCORRECT
APPLICABLE MODEL(S)/VINS
2006 Mazda3 with VINs lower than JM1 BK**** 61 473189 (Produced from July 1, 2005 to January 6, 2006)
DESCRIPTION
Some customers may complain that the clock runs slow or fast, and no matter how many times they have tried
to adjust the time, the clock display soon indicates the wrong time.
For the 2006 model year, the Information Display is what controls the clock, where in prior model years it was the audio unit that was the controlling component.
CLOCK RUNS FAST
It is possible that the customer has unintentionally performed the "Time Resetting Function", which will create
this symptom.
NOTE:
l The "Time Resetting Function" can create symptoms of the clock losing or
gaining time, even for vehicles that are outside of the listed VIN range. For
further details see TIME RESETTING FUNCTION.
When you encounter a customer complaint of an inaccurate clock where you suspect the "Time Resetting
Function" was performed, explain to the customer the time resetting function as described below and have
them continue to monitor the clock. (This function is also described in the owner¡Çs manual, "Interior
Equipment" section.)
CLOCK RUNS SLOW
Due to improper software, the clock may lose time when the ignition is turned to the ACC or OFF position.
NOTE:
l For vehicles that are outside of the listed VIN range that present this symptom,
refer to CLOCK RUNS FAST.
An updated Information Display has been introduced to address this concern. Customers having this concern
should have their information display replaced with an exchange unit as outlined in the repair procedure below.
NOTE:
l Do not remove the Information Display until the exchange unit is available and
in hand, because without the display, the driver cannot see the radio
information and climate control settings (on vehicles equipped with an
automatic climate control).
TIME RESETTING FUNCTION
While the clock is displayed with the ignition in the "ACC" or "ON" position, when the "SET" button ("INFO"
button for vehicles equipped with a TRIP COMPUTER) on the instrument panel is pressed for 1.5 seconds or
more then released, the time on the clock display is reset to the nearest hour and the minutes (and seconds)
are set to ZERO (00).
REPAIR PROCEDURE
NOTE:
l Do not remove the information display until the exchange unit is available and
in hand, because without the display, the driver cannot see the radio
information and climate control settings (on vehicles equipped with an
automatic climate control).
1. Verify customer clock concern.
2. Record radio presets.
3. Remove the center panel module. Refer to Workshop Manual section 09-20 CENTER PANEL
MODULE REMOVAL/INSTALLATION.
4. Replace the information display with a modified one. Refer to Workshop Manual section 09-20
CENTER PANEL MODULE DISASSEMBLY/ASSEMBLY.
NOTE:
l The modified part number was not changed from the original part, but all outgoing parts are to the latest modification level. Below is a
visual reference in identifying the level part equipped on a vehicle.
Modified Information Display will have a "9621" cast into the display
housing above the harness.
5. Reassemble in reverse order.
6. Reset radio presets and adjust the clock to the correct time.
7. Verify repair.
PART(S) INFORMATION
WARRANTY INFORMATION
NOTE:
l This warranty information applies only to verified customer complaints on
vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty
term information.
l Additional diagnostic time cannot be claimed for this repair.
l This part is subject to the UNITED RADIO exchange program. Claims submitted
where the Information Display was replaced without the use of an exchange
unit will be denied and/or debited.
#5
08-20-2009, 05:37 PM
2004-2006 MAZDA3 - UNUSUAL NOISE FROM FRONT WIPER LINK
APPLICABLE MODEL(S)/VINS
2004 - 2006 Mazda3 vehicles with VINs lower than JM1BK**** **475647 (produced before January 12, 2006)
DESCRIPTION
Some vehicles may exhibit a high frequency squeaking noise from the wipers when they are operating. There are two causes of this symptom:
1. The pivots make the noise.
2. The pivot housing makes contact with the shaft cap.
In either case, replacing the front wiper link assembly reserves both likely causes. The original wiper motor and wiper arms will be retained. Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Remove the windshield wiper motor. Refer to Workshop Manual section 09-19 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.
3. Remove the windshield wiper motor from the old front wiper link assembly and install it to the new front wiper link assembly. Refer to Workshop Manual section 09-19 WINDSHIELD WIPER MOTOR DISASSEMBLY AND ASSEMBLY.
APPLICABLE MODEL(S)/VINS
2004 - 2006 Mazda3 vehicles with VINs lower than JM1BK**** **475647 (produced before January 12, 2006)
DESCRIPTION
Some vehicles may exhibit a high frequency squeaking noise from the wipers when they are operating. There are two causes of this symptom:
1. The pivots make the noise.
2. The pivot housing makes contact with the shaft cap.
In either case, replacing the front wiper link assembly reserves both likely causes. The original wiper motor and wiper arms will be retained. Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Remove the windshield wiper motor. Refer to Workshop Manual section 09-19 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.
3. Remove the windshield wiper motor from the old front wiper link assembly and install it to the new front wiper link assembly. Refer to Workshop Manual section 09-19 WINDSHIELD WIPER MOTOR DISASSEMBLY AND ASSEMBLY.
#6
08-20-2009, 05:39 PM
2004-2006 MAZDA3 - PASSENGER CARPET DOES NOT FIT PROPERLY
APPLICABLE MODEL(S)/VINS^ 2004-2006 Mazda3 vehicles with VINs lower than JM1 BK**** ** 516377 (produced before April 1, 2006)
DESCRIPTION
Some vehicles may experience poor fitting carpet in the passenger footwell area where the carpet bunches up and pulls out from under the passenger's front side trim (kick panel). There is a gap between the dash insulator pad and the carpet and when the carpet is pressed down, it moves out of position and pulls out from under the front side trim.
As a mass-production change, a felt pad has been added under the carpet attached to the dash insulator pad. Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Remove the scuff plate.
3. Remove the front side trim.
4. Pull back the carpet to expose the dash insulator pad.
5. Ensure the corner dash insulator pad is positioned properly pressed down under the carpet before installing the felt pad.
6. Apply locally sourced double-sided 3M Scotch Mounting Tape (or equivalent) to the felt pad.
7. Position the felt pad on the dash insulator pad as shown (align the corner).
8. Press the felt pad firmly onto the dash insulator pad to attach securely.
9. Place the carpet back into position and install the front side trim and scuff plate.
10. Verify repair by pressing down on area of concern and confirm carpet does not pull out from under front side trim.
APPLICABLE MODEL(S)/VINS^ 2004-2006 Mazda3 vehicles with VINs lower than JM1 BK**** ** 516377 (produced before April 1, 2006)
DESCRIPTION
Some vehicles may experience poor fitting carpet in the passenger footwell area where the carpet bunches up and pulls out from under the passenger's front side trim (kick panel). There is a gap between the dash insulator pad and the carpet and when the carpet is pressed down, it moves out of position and pulls out from under the front side trim.
As a mass-production change, a felt pad has been added under the carpet attached to the dash insulator pad. Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Remove the scuff plate.
3. Remove the front side trim.
4. Pull back the carpet to expose the dash insulator pad.
5. Ensure the corner dash insulator pad is positioned properly pressed down under the carpet before installing the felt pad.
6. Apply locally sourced double-sided 3M Scotch Mounting Tape (or equivalent) to the felt pad.
7. Position the felt pad on the dash insulator pad as shown (align the corner).
8. Press the felt pad firmly onto the dash insulator pad to attach securely.
9. Place the carpet back into position and install the front side trim and scuff plate.
10. Verify repair by pressing down on area of concern and confirm carpet does not pull out from under front side trim.
#7
08-20-2009, 05:40 PM
2004-2006 MAZDA3 - 4-DOOR SEDAN - SQUEAKING NOISE FROM REAR OF VEHICLE WHILE DRIVING
APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 4-door Sedan vehicles
with VINs lower than JM1BK**** ** 498597 (produced before March 2, 2006)
DESCRIPTION
Some 4-door Sedan vehicles may exhibit a squeaking noise from around the rear package tray while driving. Due to the torsional movement of vehicle body while driving, the front package member makes contact with the package junction panel, resulting in a squeaking noise.
As a mass-production change, a spot weld has been added to the area of concern. Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Open the trunk.
3. Using a plastic Windshield Setting Tool or equivalent, gently pry open the area where the front package member makes contact with the package junction panel to provide clearance. Repeat for both sides of the vehicle.
NOTE: ^ Plastic Windshield Setting Tool (Part Number IS742 - available from Equalizer at 800-334-1334) or similar available through a local supplier.
^ If you substitute a flat screwdriver, wrap the end of the screwdriver with tape so it will not damage the vehicle.
4. Apply spray grease to the area of concern pried open in the previous step.
APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 4-door Sedan vehicles
with VINs lower than JM1BK**** ** 498597 (produced before March 2, 2006)
DESCRIPTION
Some 4-door Sedan vehicles may exhibit a squeaking noise from around the rear package tray while driving. Due to the torsional movement of vehicle body while driving, the front package member makes contact with the package junction panel, resulting in a squeaking noise.
As a mass-production change, a spot weld has been added to the area of concern. Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Open the trunk.
3. Using a plastic Windshield Setting Tool or equivalent, gently pry open the area where the front package member makes contact with the package junction panel to provide clearance. Repeat for both sides of the vehicle.
NOTE: ^ Plastic Windshield Setting Tool (Part Number IS742 - available from Equalizer at 800-334-1334) or similar available through a local supplier.
^ If you substitute a flat screwdriver, wrap the end of the screwdriver with tape so it will not damage the vehicle.
4. Apply spray grease to the area of concern pried open in the previous step.
#8
08-20-2009, 05:41 PM
MULTI-MODEL - KEY REMINDER CHIME KEEPS CHIMING OR KEYLESS ENTRY INOPERATIVE
BULLETIN NOTE: This bulletin supercedes the previous bulletin 09-32/06 issued on 7/18/06. The SUBJECT has been revised.
APPLICABLE MODEL(S)/VINS^ 2004 - 2006 Mazda3 vehicles with VINs lower than JM1 BK**** **526084 (produced before April 18, 2006)
^ 2006 Mazda5 vehicles with VINs lower than JM1 CR**** **125853 (produced before April 18, 2006)
DESCRIPTION
On some vehicles, the key reminder chime keeps chiming even though the key is pulled out of the ignition. In addition, the doors cannot be locked with the keyless entry system. This is caused by an internal failure from a contact plate that was not properly molded.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Record the customer's radio station presets.
3. Disconnect the negative battery cable.
4. Remove the column cover. Refer to Mazda3 Workshop Manual section 09-17 COLUMN COVER REMOVAL/INSTALLATION or Mazda5 Workshop Manual section 09-17 COLUMN COVER REMOVAL/INSTALLATION.
5. Remove the ignition switch from the steering lock.
6. Disconnect the connector from the ignition switch by pulling down on the lever.
7. Reconnect the connector to the new ignition switch.
8. Install the new ignition switch.
9. Install the column cover.
10. Reconnect the negative battery cable.
11. Verify repair.
12. Reset the customer's radio station presets.
BULLETIN NOTE: This bulletin supercedes the previous bulletin 09-32/06 issued on 7/18/06. The SUBJECT has been revised.
APPLICABLE MODEL(S)/VINS^ 2004 - 2006 Mazda3 vehicles with VINs lower than JM1 BK**** **526084 (produced before April 18, 2006)
^ 2006 Mazda5 vehicles with VINs lower than JM1 CR**** **125853 (produced before April 18, 2006)
DESCRIPTION
On some vehicles, the key reminder chime keeps chiming even though the key is pulled out of the ignition. In addition, the doors cannot be locked with the keyless entry system. This is caused by an internal failure from a contact plate that was not properly molded.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Record the customer's radio station presets.
3. Disconnect the negative battery cable.
4. Remove the column cover. Refer to Mazda3 Workshop Manual section 09-17 COLUMN COVER REMOVAL/INSTALLATION or Mazda5 Workshop Manual section 09-17 COLUMN COVER REMOVAL/INSTALLATION.
5. Remove the ignition switch from the steering lock.
6. Disconnect the connector from the ignition switch by pulling down on the lever.
7. Reconnect the connector to the new ignition switch.
8. Install the new ignition switch.
9. Install the column cover.
10. Reconnect the negative battery cable.
11. Verify repair.
12. Reset the customer's radio station presets.
#9
08-20-2009, 05:42 PM
2004-2006 MAZDA3 - PASSENGER CARPET DOES NOT FIT PROPERLY
APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 vehicles with VINS lower than JM1 BK**** ** 516377 (produced before April 1, 2006)
Some vehicles may experience poor fitting carpet in the passenger footwell area where the carpet bunches up and pulls out from under the passenger's front side trim (kick panel). There is a gap between the dash insulator pad and the carpet and when the carpet is pressed down, it moves out of position and pulls out from under the front side trim.
As a mass-production change, a felt pad has been added under the carpet attached to the dash insulator pad.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Remove the scuff plate.
3. Remove the front side trim.
4. Pull back the carpet to expose the dash insulator pad.
5. Ensure the corner dash insulator pad is positioned properly pressed down under the carpet before installing the felt pad.
6. Apply locally sourced double-sided 3M Scotch Mounting Tape (or equivalent) to the felt pad.
7. Position the felt pad on the dash insulator pad as shown (align the corner).
8. Press the felt pad firmly onto the dash insulator pad to attach securely.
9. Place the carpet back into position and install the front side trim and scuff plate.
10. Verify repair by pressing down on area of concern and confirm carpet does not pull out from under front side trim.
APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 vehicles with VINS lower than JM1 BK**** ** 516377 (produced before April 1, 2006)
Some vehicles may experience poor fitting carpet in the passenger footwell area where the carpet bunches up and pulls out from under the passenger's front side trim (kick panel). There is a gap between the dash insulator pad and the carpet and when the carpet is pressed down, it moves out of position and pulls out from under the front side trim.
As a mass-production change, a felt pad has been added under the carpet attached to the dash insulator pad.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Remove the scuff plate.
3. Remove the front side trim.
4. Pull back the carpet to expose the dash insulator pad.
5. Ensure the corner dash insulator pad is positioned properly pressed down under the carpet before installing the felt pad.
6. Apply locally sourced double-sided 3M Scotch Mounting Tape (or equivalent) to the felt pad.
7. Position the felt pad on the dash insulator pad as shown (align the corner).
8. Press the felt pad firmly onto the dash insulator pad to attach securely.
9. Place the carpet back into position and install the front side trim and scuff plate.
10. Verify repair by pressing down on area of concern and confirm carpet does not pull out from under front side trim.
#10
08-20-2009, 05:43 PM
2004-2006 MAZDA3 - FRONT BRAKE SQUEAK WHEN COLD
NOTE :This bulletin replaces 04-001/05. Please update your records accordingly.
BULLETIN NOTE
This bulletin supersedes the previous bulletin 04-001/05, issued 06/03/2005. The APPLICABLE MODEL(S)/VINS, REPAIR PROCEDURE, PART(S) INFORMATION, and WARRANTY INFORMATION have been revised.
APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3
^ 2.0L with VINS from JM1BK****41 100001 to JM1BK****61 433115 (produced before September 19, 2005)
^ 2.3L vehicles with VINS lower than JM1BK****41 133301 (produced before December 17, 2003)
^ 2.3L with VINS from JM1BK****41 133302 to JM1BK****61 433115 (produced before September 19, 2005)
DESCRIPTION
When applying the brakes during slow speed driving and in cold weather conditions, some vehicles may have a squeak noise coming from the front brakes. This may be caused by resonance in the pad, disc, and caliper.
A modified mounting support for the front brake calipers and modified pads have been introduced to correct this concern.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
Perform the appropriate repair procedure as follows:
^ 2.3L vehicles with VINS lower than JM1BK****41 133301 (produced before December 17, 2003) perform REPAIR PROCEDURE "A".
^ 2.OL with VINS from JM1BK****41 100001 to JM1BK****61 433115 (produced before September 19, 2005) perform REPAIR PROCEDURE "B".
^ 2.3L with VINS from JM1BK****41 133302 to JM1BK****61 433115 (produced before September 19, 2005) perform REPAIR PROCEDURE "C".
REPAIR PROCEDURE "A"
1. Verify customer concern.
NOTE :
If service bulletin 04-001/05 was already performed on this vehicle, the updated caliper mounting supports will already be installed. Verify that the updated supports are installed through visual inspection.
^ If updated caliper mounting supports are not installed, continue with REPAIR PROCEDURE "A".
^ If updated caliper mounting supports are installed, proceed to REPAIR PROCEDURE "B".
2. Replace front brake caliper mounting support assemblies and front pad & shim set with the modified parts according to Workshop Manual (section 04-11 FRONT BRAKE (DISC) REMOVAL/INSTALLATION).
3. Procede to REPAIR PROCEDURE "B".
REPAIR PROCEDURE "B"
1. Verify customer concern.
2. Replace front pad and shim set with the modified parts according to Workshop Manual (section 04-11 FRONT BRAKE (DISC) REMOVAL/INSTALLATION).
NOTE :This bulletin replaces 04-001/05. Please update your records accordingly.
BULLETIN NOTE
This bulletin supersedes the previous bulletin 04-001/05, issued 06/03/2005. The APPLICABLE MODEL(S)/VINS, REPAIR PROCEDURE, PART(S) INFORMATION, and WARRANTY INFORMATION have been revised.
APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3
^ 2.0L with VINS from JM1BK****41 100001 to JM1BK****61 433115 (produced before September 19, 2005)
^ 2.3L vehicles with VINS lower than JM1BK****41 133301 (produced before December 17, 2003)
^ 2.3L with VINS from JM1BK****41 133302 to JM1BK****61 433115 (produced before September 19, 2005)
DESCRIPTION
When applying the brakes during slow speed driving and in cold weather conditions, some vehicles may have a squeak noise coming from the front brakes. This may be caused by resonance in the pad, disc, and caliper.
A modified mounting support for the front brake calipers and modified pads have been introduced to correct this concern.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
Perform the appropriate repair procedure as follows:
^ 2.3L vehicles with VINS lower than JM1BK****41 133301 (produced before December 17, 2003) perform REPAIR PROCEDURE "A".
^ 2.OL with VINS from JM1BK****41 100001 to JM1BK****61 433115 (produced before September 19, 2005) perform REPAIR PROCEDURE "B".
^ 2.3L with VINS from JM1BK****41 133302 to JM1BK****61 433115 (produced before September 19, 2005) perform REPAIR PROCEDURE "C".
REPAIR PROCEDURE "A"
1. Verify customer concern.
NOTE :
If service bulletin 04-001/05 was already performed on this vehicle, the updated caliper mounting supports will already be installed. Verify that the updated supports are installed through visual inspection.
^ If updated caliper mounting supports are not installed, continue with REPAIR PROCEDURE "A".
^ If updated caliper mounting supports are installed, proceed to REPAIR PROCEDURE "B".
2. Replace front brake caliper mounting support assemblies and front pad & shim set with the modified parts according to Workshop Manual (section 04-11 FRONT BRAKE (DISC) REMOVAL/INSTALLATION).
3. Procede to REPAIR PROCEDURE "B".
REPAIR PROCEDURE "B"
1. Verify customer concern.
2. Replace front pad and shim set with the modified parts according to Workshop Manual (section 04-11 FRONT BRAKE (DISC) REMOVAL/INSTALLATION).