Clunk Updates

Here is the email I sent to the two Mazda engineers at Mazda USA. I don't care if they get pissed, this is ******* ridiculous. We shall see, they've been responsive in the MSP hesitation issue, so maybe they'll be responsive with the clunk:
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Hello to both of you,
First off, let me apologize for sending email to both of you. I realize that email directly from a customer is the last thing you want, and I would feel the same way as well. But after dealing with this issue for two years, I have finally decided to send it to those who might give a darn.

For two years now, I have sincerely enjoyed my Laser Blue 2001 Mazda MP3. Its looks, style, and handling are simply incredible. This was my first purchase of a brand new car, and I was sincerely looking forward to it. However, for the past two years, there has been a problem.

About three months after I began driving my new car, I noticed a weird noise coming from the back. I first thought it was a blown strut or loose spare tire, but it was instead the now infamous clunk (at least infamous to us owners). For two years, I routinely go to my dealer every couple of months and get my bushings replaced. I am not sure if all new cars require this amount of service, but I doubt it.

The reason I am emailing is to ask about a fix. I understand that Mazda USA has nearly completed a fix for the Mazdaspeed Protege "hesitation" issue. It annoys me to see a fix come out for a car months after it was released, while those of us with our two-year-old cars have been left on the backburner. Also, every time I contact Mazda USA to make an inquiry about a fix, I receive canned replies of "We are not aware of this situation". This makes me nervous.

Mazda has come out with two revisions of the rear swaybar bushings that are now being used to replace our bushings. These are also the same bushings that come on a Mazdaspeed Protege. However, several Mazdaspeed owners are now becoming all to familiar with a strange sound coming from their trunk. Please realize that this noise isn't the only problem. The back end becomes noticeably loose when the problem occurs; the car does not handle as advertised when the problem occurs!

I could bore you with an attachment of a couple of hundred un-satisfied people who have the same problem I speak of, but I will not put you through that. Believe me, we exist, and we're getting irritated.

A lot of us have come to believe after getting tidbits of information from a certain company who designed the prototype MP3, that the problem really isn't in the bushing itself, but the use of Mazda OEM endlinks on a suspension that is so much stiffer. A simple look at Racing Beat's description of the prototype MP3 on their website shows that they designed a much beefier endlink setup than Mazda decided to use.

I am not a car engineer. I do not claim to know what I'm talking about, but I'm starting to crave an answer, and I'm hoping we'll get one soon. Its been two years. Our warranties are disappearing. What happens when our warranties are complete, and we go in every two months to pay for replacement bushings? Well, I sure don't want to think about that.

I appreciate the time from both of you. Again, I apologize for contacting you directly, but desperate times call for desperate measures! Take care.

Sincerely,
Chris Sobotkiewicz
2001 Mazda MP3
Madison, WI
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Craig, "live free or die" right? it helps out a lot... :)

yeah, the inspection is only like $20 then you've got the sniffer tests and other crap...its all bs redtape designed to make money for the state.


Doomer, that's a great letter; well put.
One addition to your analysis...as the car gets looser, and time goes on, and bushings are not replaced immediately after starting to make the noise, the endlinks, and swaybar become damaged as well (along with other parts I'm sure), thus, you'd be replacing much more than just some rubber bushings after the warranty, and that could get even more expensive, like 5000% or more more expensive...just wanted to add some fuel to the fire here, sorry.
 
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just so you guys know i am at about 3000miles clunk free so far. Not a sound from my rear yet. Last time i had new bushings put in i put a small (1/8") piece of vinyl between bushing and frame, and it has felt solid so far. I know its only 3000 miles but that is more than usual.

I know this isnt a perm. fix, but it might help a lilttle.

If there isnt a fix soon, im gonna order some AWR endlinks and see if that helps. The stock endlinks i could bend in half with one hand.
 
AARRRGGGGHHHH!!!!

Wicked letter Doomer!! I just went in to my dealer today and demanded new bushings for my MP3. The GM said he was going to call the district manager of mazda canada to get some answers for me. He called me back no more then 4 hours later and told me what the district manager said. He said that they will NOT be replacing any parts anymore, that they are very well aware of the problem and that mazda is working on a fix (don't know what kind of fix though). he also said that a date has not been confirmed of when they expect the new parts to come out for us all. As well he mentioned that since they are not going to be replacing any parts, he said just drive your car and when the new parts arrive they will install them, as well as fix any other parts that have been effected by this (sway bar etc.) I don't know how much I or we can trust these guys since it has now been two years of these problem. I at least wanted you all to know what I have been told. It basically sounds like the same run around that we have all been getting. Hopefuly though there is some truth to this all and the can get to the bottom of this before I decide to run my car off a cliff....
later
j
 
sound like the end is near.

I'll be at my dealer tomorrow, i will ask if they heard anything.
Im getting a cv joint replaced. Hopefully they will do it under warrenty*cross fingers*
 
Hey all, here's an update from my dealer...:rolleyes:
They would NOT replace the bushings either saying that they contacted MNAO and they said they would not pay for the replacement as there will be a permanant fix in the next 3-4 weeks...I'll believe it when I see it...not the dealers fault at all.

Needless to say, it got worse, my inspection was up, and now after 34k faithfull miles (maybe 10k+ on snows though:)), my tires are done, they won't pass it without new tires...!chaching!, another $500 or so on top of the $80 for the inspection, and $30 or so for oil change (I'd do it myself, but I really don't have time to scratch my own ass anymore, and since the car was there, $15 for the labor and $15 for the Mobil 1 I supply, whatever...

So chime in boys, what tires do I get? At this point, I'll sacrifice grip for quietness...so any recs, throw them at me.
 
My ES100 yokos have treated me well. They are not as loud, have similar wet traction and much better off the line traction. Corner traction suffer though but for about $100/tire as apposed to the dunlops $190/tire.
 
Cool, thanks craig. Right now they are leading the pack in feedback on Tirerack, but the price on the Dunlops is down to 137 (not like I'm buying them though :D)
 
MNAO told me a month ago that a fix should be coming in about two weeks. If you do the math, that was two weeks ago. My dealer told me that new bushings from Canada were scheduled to be put on my car when they come in. Again, that was two weeks ago, but my dealer did put on new 156D's last friday to hold me over until these new bushings come in. I also won't hold my breath.
 
Man I hope so, I made an appt. next week and they better change mine or else I will kick somebodys ass. Sorry but I am getting mad as hell about this clunk crap......
 
RESPONSE!!!
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Thank you for your input and commitment to Mazda. I can assure you that we
take this kind of problem very serious and are currently developing a
legitimate solution. Please contact me middle of October if you have not
received a solution.



Truman Pollard
Chief Designer
Mazda Design North America
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(yippy)
Lets hope this is correct! It seems to confirm little rumors others have posted in this thread. We shall see.

Chris
 
Hey Doomer, that is AWESOME news!!!!!! In my efforts to get the MSP's hesitation fixed I never got a response directly from Truman despite many emails sent directly to him -- he always forwarded it to a "lower" person to repond.

So the fact that you got a response AND he told you to contact him again in October is extremely encouraging. And this couldn't come at a better time because the clunk is starting to annoy me even MORE than the damn hesitation on the MSP. It's clunking CONSTANTLY now. Ugh.
 
Good to see thats a response form a designer and not another customer service ass clown!
 
Indeed it is. I'm kind of baffled that dealers are refusing the replace the parts right now until a permanent fix is available. My dealer was out of the bushings for a month, and then I didn't get around to making an appointment for another month. After 3 or 4 months of the clunk, the usual bushing replacement turned into a bushing replacement, endlink replacement, and rear strut replacement! Not too cost effective. Hmph.

I'm keeping my fingers crossed :).

Oh and hey, girth, thanks for pointing me to the thread with the email addresses. And let me know if you guys do a Milwaukee meet, I am from the area and hope to move back from Madison next year.

Chris
 
Thanks for helping doomer. I gotta say though, I sent 3 such "nice and simple" letters to Mazda and never got so much of an email. Then I sent THE letter that wasn't so nice,and was much more detailed, and hence we finally got an admittal from Mazda. IT's amazing what a few words like law suit and sue( spelling?) can do.

All this helps guys! Many voices are louder then one!

Oh, and there's been more then just 2 releases of the bushings
 
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i mention it to my dealer today, he said last he heard was to use the teflon tape... he said he will try and find out.
 
Oh thank god. This is very good news indeed. Funny though, I had my bushings replaced exactly 2 weeks ago. They never said anything about not putting in any more replacment parts. Although they did have a parts shop with all the mazdaspeed parts, shock, and the sway bar kits so they might have just read the TSB, grabbed a couple of bushings in stock and figured they'd just get them replaced when they submitted the warranty claim. I switched dealers that I usually go to. Every time I had to get them replaced it took atleast 3 weeks to get the bushings in. So I'm glad I switched.

Great news though. Hopefully it's true. And not a moment to soon, I have 47,568 miles on my car. Hopefully I can hold out for 3-4 weeks without busting the warranty.
 
I'd hope that MNAO would honor your warranty should you go over...if not, I'd fly out to Cali and punch someone.
 
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