Exhaust (resonator) and heat shield issues- warranty extended FYI!

IgoZoom

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2012 Mazda CX-9 GT FWD, Crystal White Pearl, Bose/Moonroof
I wanted to share my most recent issue with my 2012 CX-9. This is only the second problem that I've experienced in 45k miles and both have been warrantied, so I still love my CX-9 as much as ever!

The brake booster failed about three months ago at 40k miles. The 3yr/36k warranty was expired and the brake booster isn't covered under the 5yr/60k powertrain warranty. Thankfully, Mazda has extended the warranty on the brake booster and related parts to 9yrs and something like 140k miles for 2010-2012 CX-9s. In my opinion, they should have done a recall because of the potential safety issues. Stopping a 4000+ pound SUV without the any power assist for the brakes can be a scary and dangerous thing, but I'm still glad they covered it.

After the brake booster repair in late May, I began hearing an intermittent metallic tapping/thrumming/vibration-type noise under very light throttle. It was very sporadic at first, but after a few weeks, I started hearing it at least a few times per day. My first instinct was that a loose or damaged heat shield was the problem and that turned out to be partially true. But several parts of the exhaust system also had to be replaced including the resonator pipe and a few other things I've never heard of. The parts that they replaced alone would have retailed for over $1100!

I wasn't sure if the exhaust would fall under the powertrain warranty or not, but it turned out to be a non-issue. The Service Manager informed me that the exhaust issue was also covered by an extended warranty on the defective parts. I'm not sure what year models this affects nor the length of the warranty extension, but I wanted to let you guys know that it does exist. I can't even find a TSB related to it, but if you have exhaust problems with your CX-9, maybe this will apply to you also! =)

It took 23 days to get the parts, but since the car was safely drivable, it really didn't bother me much.

Now I get to wait until my turn to have the front suspension parts replaced that were announced in the recall on 2007-2014 CX-9s today! I'm in the last group, the first group being the oldest ones and the second group being other owners in Northeastern states where road salt is used. I'm glad they're doing a full-scale recall instead of the 'secret' warranty this time around.....even if there is a backlog on parts!
 
If you read the official nhtsa recall info, there is no remedy available for the balljoints. dealers will inspect them for looseness and replace the control arms if neccessary. I.e. "your balljoints are fine, but thanks for leaving your car with us all day." Sorry 2 hear about your woes though man! My 08 hasnt had any problems ever other than small brakes that suck and 1 spark plug that i messed up.
 
My 08 hasnt had any problems ever other than small brakes that suck and 1 spark plug that i messed up.

Actually, I forgot to mention my brakes. The rotors were replaced under warranty around 10k miles due to vibration. By 17k miles, the vibration was back and they insisted on 'resurfacing' the rotors. (Let's make them thinner and see if that helps.....NOT!) I finally conceded that the dealer would never fix the problem correctly. I bought a set of high-quality slotted/vented rotors and ceramic pads for the front (about $200 out of pocket and a friend installed them for $100). Almost 30k miles later, they still perform better than when the car was new!
 
I put on centric e-coated rotors myself, and they have lasted about 45k but suck again. I would pay for a Brembo big brake kit if only it was available for the cx-9. The brakes are so undersized oem its not even funny.
 
If you read the official nhtsa recall info, there is no remedy available for the balljoints. dealers will inspect them for looseness and replace the control arms if neccessary. I.e. "your balljoints are fine, but thanks for leaving your car with us all day."

?????

From NHTSA:

"REMEDY:
Mazda will notify owners, and dealers will replace both the left and right lower control arms, free of charge."


Report Receipt Date: JUL 20, 2015
NHTSA Campaign Number: 15V451000
Component(s): SUSPENSION
Potential Number of Units Affected: 193,484

http://www-odi.nhtsa.dot.gov/owners...Category=R&searchCriteria.nhtsa_ids=15V451000

the reason (i suspect) mazda WILL replace the control arms is because NHTSA has reports of them breaking w/out any warning.

"The company found one car with this problem in May 2012 and later modified the parts on later CX-9s in January 2014. However, Mazda did not consider a recall since it considered checking these loose joints as part of regular CX-9 maintenance. Also, Mazda said it thought the joint would not break without the driver first hearing a noise, although NHTSA reports found they could indeed break without any warning."

http://blog.caranddriver.com/mazda-recalls-193000-cx-9-crossovers-for-rusty-suspension-parts/
 
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