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We are writing to you to inform you of a product recall regarding the Lightweight Crank Pulley you purchased from us on March 14th 2012
As you may be aware in the summer of 2011, CorkSport announced a recall of this product due to what we believed to be anodization issue with the manufacturing process. After the recall was completed, we went through the process of design revisions and quality assurance testing to improve the product and re-released it in August of 2011.
In the last several weeks we have seen a new failure occurrence that has given us cause to conclude that this product does not meet the quality standards that we expect in our products or want to provide to our customers.
The failure occurrence on the pulley appears to happen in approximately 8% of cases and within the first month or so of installation. Before it fails you may notice a vibration noise coming from the crank area of the engine. This is the timing ring backing away from the pulley. Once it fails the ring will be free which will disable the vehicle. It should not cause any major harm to the engine. However, the car will not restart without removing the ring and pulley and replacing it. We have also seen in one instance that the timing ring took out the crank sensor as well requiring a replacement.
Many of you have been running your pulley for many months and not seen any such occurrence of failure. The design employs technology that has been used successfully in other applications without issue and to this day, the pulley that we have been running on our Mazdaspeed 3 for two years and on the Mazda 2 in extreme driving conditions for over a year have yet to fail, but because we want to maintain trust with our customers and be confident standing behind the quality of the parts we sell on the market, we have decided to pull them from the market permanently based on the recent failures that have occurred.
We want to give you the option to return your pulley to us at our expense for credit. In the event you choose to keep your pulley, we can no longer warranty it. We want you to make an informed decision and hope we have given you all of the necessary information to do so.
We apologize to you for the inconvenience this recall has caused. This is the first time in our history we have pulled a product from the market for a defect. We are committed to providing the highest quality products and service to our customers and their vehicles. We will be offering anyone who has purchased the pulley the option to return it to CorkSport for credit. We will be contacting each of our customers who have purchased this product to discuss options for return and credit.
We hope our commitment to you and to the Mazda community is evident and want all of our customers to know that we stand behind you 100%.
Please contact me to discuss options for returning your pulley and we will make the needed arrangements to have it returned.