2024 Mazda CX-90 Plug-In Hybrid Electrical Problems

I am reporting serious safety concerns with my Mazda CX-90 PHEV (leased, manufactured September 2023). These issues create unacceptable risk to occupants and other road users. Multiple Severe Recalls: My vehicle has had at least four major recalls: • 6323J – Engine & Motor Shutdown: Complete loss of propulsion without warning. • 7024J – ECU Software Failures: Loss of drive power and restart failures. • 24V817000 – EV Mode Power Loss: Sudden propulsion loss in EV mode. • 6724E – Sudden Braking: Automatic braking without cause. These defects could lead to crashes or fatalities. Hybrid System Malfunctions: Two recent “Hybrid System Malfunction” warnings required dealer visits. These failures could cause the car to shut off while driving—even at highway speeds. • First incident: Battery-related issue. • Second incident: Triggered by a loud noise during startup, impacting the AVAS system. A loud noise should never disable a family vehicle, indicating a design flaw. Charging Safety Issues: Charging via a standard outlet caused flickering lights and breaker buzzing in my house. A licensed electrician diagnosed harmonic distortion from the onboard charger. I spent $7,500 on electrical upgrades (dedicated EV line and panel upgrade) to charge safely. Manufacturer Response: I have had an open case with Mazda corporate for nearly two weeks. They refuse to acknowledge overall vehicle safety or provide written documentation confirming safety. Request: I urge NHTSA to investigate whether these defects represent a systemic safety issue in Mazda CX-90 PHEV models and take appropriate regulatory action

NHTSA ID

11704628

Incident

Nov 25, 2025

My 2024 Mazda CX-90 continues to have a malfunctioning fuel gauge despite multiple dealer visits and the recall repair (Recall 25V568). The dealer confirmed the issue was fixed, but it is not. The digital fuel gauge does not update in real time. It remains stuck for long distances and only partially recalibrates after restarting the car. For example, on November 5, 2025, I drove more than 60 miles, but the gauge dropped by only about 10 miles. After turning the ignition off and on, the gauge adjusted slightly but still did not reflect the true fuel level. Photos from that day are attached. I have serious safety concerns. The recall notice states: “If the vehicle incorrectly indicates an inaccurate fuel level, there is a chance of unexpectedly running out of fuel while driving. This would result in an engine stall and vehicle being unable to restart, increasing the risk of a crash.” This issue persists even after the recall service was completed, suggesting that the current fix may not fully resolve the defect. This has been an ongoing issue. I visited the dealership again on Nov 5th, 2025.

NHTSA ID

11697781

Incident

Nov 5, 2025

On occasion (several times in a month) I will drive the car listening to the radio. I then park for a short time and turn the car on and drive away when I notice that the radio isn;t on as it was when I parked. I then have to pull over, park the car, shut off the engine then restart. Now the redio comes on. I am concerned that other safety items are also non functioning when this happens. The dealer has been no help.

NHTSA ID

11691433

Incident

Oct 4, 2025

The hybrid battery and hybrid system malfunctioned. The vehicle emitted a strong rotten-egg odor (consistent with hydrogen sulfide gas) inside the cabin from [XXX] to [XXX]. The hybrid system warning light first appeared on [XXX]. On [XXX], the air conditioner did not work while driving, and on other occasions it failed to turn on until the engine was restarted. On August 5, 2025, the vehicle was serviced for a related recall, but the warning light returned shortly afterward. From [XXX] to [XXX], my children (ages [XXX] and [XXX] ), my elderly mother, and I were exposed to fumes inside the cabin. We experienced headaches, nausea, and dizziness. On one occasion, my mother nearly fainted after dinner while visiting, which coincided with her exposure to the odor. The dealership did not warn me that the hybrid warning light could be associated with the odor or that an odor would be hazardous, so I continued driving the vehicle during this period. On September 3, 2025, the dealership confirmed the hybrid system malfunction, deemed the car unsafe to drive, and ordered a replacement battery. The vehicle was out of service until September 15, 2025, when the entire hybrid battery was replaced. The dealership inspected the vehicle multiple times, and Mazda corporate (Customer Experience Center case manager) was notified. The component was replaced under warranty, but the event created a significant safety risk due to exposure to toxic fumes and the potential for hybrid system failure while driving. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11687732

Incident

Jul 20, 2025

Ever since the lease of this vehicle on January 2025 we’ve had problems with the brake/rotors took it in twice for that. As of recent August 2025, we took it in for loss of power going up a hill, hybrid malfunctioning electrical system going out. Dealership gave it back saying everything was fine. We took it on August 29, 2025 to Colorado vehicle failed to perform loss of power going up the mountain almost got hit by a vehicle because I was in a fast lane with my family had to pull over with whatever power I had left in the engine (not the battery). I mean the vehicle just keeps failing to perform as it should as well on the way back. It had the same issues but as severe going to Colorado.Vehicle does not change gears going uphill. When we stopped in Vegas for fuel, fuel door did not open it & malfunctioned. So vehicle does not perform well in cold and hot weather AWD system does not work at all. We feel a jerking, we hear a whistling’s type of noise that the dealership fell to inspect. Per them everything worked fine but when we took it to Colorado this weekend for Labor Day, vehicle underperformed with extreme safety concerns and we contacted Mazda, but they fell to listen to our concerns and say the vehicle is fine but when you drive the vehicle, it does not perform as it should and is a safety hazard to us and anybody around us due to a loss of power and everything I described above.

NHTSA ID

11684407

Incident

Aug 29, 2025

On two separate occasions, my young children were locked inside the vehicle, and on one of the two occasions my elderly mother was also locked inside. In all incidents, the doors and windows remained closed and would not unlock, even when attempting to use the key fob. Specifically, after parking, I exited the driver’s seat and closed my door. When I went to open the rear doors to get my children out of their car seats, the rear doors were locked and could not be unlocked by the key fob. The same occurred when my elderly mother was in the vehicle. Each time, the car was in hot conditions, and we were fortunately able — after some struggle — to unlock the doors and remove them from the vehicle. This presents a serious safety risk, particularly in warm weather and with young or elderly passengers who cannot exit the vehicle themselves. I am currently pursuing a lemon law claim for this vehicle, but I also wanted to formally report this defect because of the danger it poses.

NHTSA ID

11673421

Incident

Jul 12, 2025

Braking System and Infotainment Malfunctions — 2024 Mazda CX-90 PHEV Vehicle: 2024 Mazda CX-90 PHEV Incident Dates: June 1, 2024 June 16, 2024 June 30, 2025 Ongoing (infotainment issue) Summary of Complaint: I am reporting multiple safety-related concerns with my 2024 Mazda CX-90 PHEV involving both the braking system and the infotainment/electrical system: 1. Delayed Brake Engagement – June 1, 2024: While stopping for a pedestrian crossing the street, I pressed the brake pedal and the vehicle lunged forward before the brakes fully engaged. The delay in braking caused the vehicle to move forward several inches before stopping, nearly endangering the pedestrian. It felt as if the brakes did not respond immediately when applied. 2. Sudden, Unnecessary Braking – June 16, 2024: While following a vehicle that was slowing down to make a right turn, the CX-90 PHEV abruptly and aggressively braked on its own, despite sufficient following distance and no imminent collision risk. The rapid deceleration nearly caused the vehicle behind me to rear-end us. This appeared to be triggered by the vehicle’s automated braking or forward collision system reacting too strongly. 3. Infotainment System Failure – Ongoing / June 30, 2025: The infotainment system frequently restarts itself, shutting down entirely and rebooting without warning — particularly while driving in larger cities. On June 30, 2025, the system completely failed, and a warning appeared on the dashboard stating that the vehicle needed service. After shutting down and restarting the vehicle, the message disappeared. However, this intermittent failure creates a serious distraction and potential safety hazard while driving.

NHTSA ID

11670696

Incident

Jun 1, 2025

- Serious safety issue: car stopped suddenly in the middle of traffic - Errors appeared: Hybrid System Malfunction, “vehicle can not be driven” and “Electrical Leakage in Hybrid System Detected” - Would not come out of park, had to be towed to Mazda dealership - Picked up car and after 15 min of driving the 'hybrid malfunction' light came back on - Car was returned to Mazda dealership for testing

NHTSA ID

11664266

Incident

May 28, 2025

Issue Summary: Since December 27, 2024, my vehicle has experienced a hybrid malfunction and leakage issue three times. Each time this occurs, the vehicle becomes completely inoperable and cannot move, requiring a tow truck to take it to the dealership. Since December 27, 2024, my car has been in the shop four times, yet the issue persists. This raises serious reliability and safety concerns, as the vehicle can suddenly become unusa

NHTSA ID

11644694

Incident

Dec 27, 2024

Received Hybrid Battery Malfunction and Electrical Leakage Detection alerts two weeks ago. Dealer has not been able to fix. First they said it was the water heater, then they said my radiator was leaking and I need a new one. Estimated 4 additional weeks for repair.

NHTSA ID

11644305

Incident

Feb 8, 2024

While vehicle was in motion, warning light came on stating “engine malfunction, have the vehicle inspected”. Engine light stays illuminated. The message and light now appear at startup

NHTSA ID

11641492

Incident

Feb 5, 2025

At approximately 16:50 engine malfunction warning light appeared and dealership was notified. Appointment scheduled for 4 days after. At 17:21 car began swerving uncontrollably along I80 with warning “engine malfunction, have the vehicle inspected.” The car was shaking violently and veered off the road into the ditch between the eastbound and westbound highway. The car was totaled. Review of the vehicle app indicated that just before the crash at 17:19 several critical vehicle malfunctions messages appeared. The vehicle crashed at 17:21.

NHTSA ID

11641436

Incident

Nov 21, 2024

The contact owns a 2024 Mazda CX-90. The contact stated while driving at approximately 3 MPH, the vehicle unintendedly accelerated; however, the accelerator pedal was not being depressed during the failure. No warning light was illuminated. The vehicle was taken to a dealer and was diagnosed that a software update was needed. The vehicle was repaired; however, the failure persisted. The manufacturer was notified of the failure. The failure mileage was approximately 3,000.

NHTSA ID

11631804

Incident

Dec 20, 2024

Mileage

3,000 mi

I was driving my 2024 CX90 PHEV when a warning about an electrical leakage in the hybrid system was detected. I brought it home and parked in my garage. I called the dealership and they told me to bring it in. When I started to leave, the car would not shift out of park and bricked up. A towing service had to drag it out of my garage. My concern is that there is no limp mode or any way to switch to the gasoline engine when this happened. Had there been a fire in the battery, I would not have been able to get it out of my garage, putting our house and children at risk. Also, had it locked up on a highway, an accident could easily happen. After the dealership dragged it off of the rollback, they couldn’t even get the car to move. They told me that they would have to order special tools to be able to get the car to move. Along with the steering recall that worked for about a month, the steering rack had to be replaced, and the failure of the electrical system, I feel like this car is unsafe to drive. Thank you.

NHTSA ID

11623076

Incident

Oct 16, 2024

On my way to drop kid to school all of a sudden the car gave up power and shuddered with engine malfunction and I-drive malfunction warning. Check engine light came on. This is risky because another vehicle could have smashed into us if on highway or high speed. Research shows that a whole lot of people have this identical issue.

NHTSA ID

11620262

Incident

Oct 14, 2024

Warning Alert for Hybrid System Malfunction also I Activsense partially disabled notice on screen

NHTSA ID

11618993

Incident

Oct 9, 2024

Mazda CX 90 PHEV. When charging on 110 standard outlet or 240v dedicated breaker - Chargepoint charger, the car onboard charger/inverter backfeeds a loud buzzing / humming back through the electrical wire to the electrical panel. It also causes a buzzing/humming in other appliances and causes led lights in the house to flicker. This is with a 100amp breaker panel and a new upgraded 200amp breaker panel. May cause electrical issues up to electrical fire in other areas of the home. Scheduled diagnostic test in vehicle 10/1/24, but other owners report same issue on Mazda CX 90 online forums.

NHTSA ID

11615291

Incident

Sep 5, 2024

The contact owns a 2024 Mazda CX-90. The contact stated that on several occasions while driving at various speeds, the message "Vehicle Failure Detected - Hybrid System Malfunction", "Possibility of Restricted Power Output", "I-Activsense System Malfunction", "Dynamic Stability Control Malfunction", and "Push button Start System Malfunction" were displayed. Additionally, the I-Activsense warning light was illuminated. The vehicle was taken to a dealer where it was diagnosed that an unknown software needed to be updated. The vehicle was repaired but the failure reoccurred. The vehicle was taken back to the same dealer where it was diagnosed that the connector to the battery needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 3,960.

NHTSA ID

11610405

Incident

Aug 1, 2024

Mileage

3,960 mi

July 11, 2024 – Odometer – 7,604, Gas – Full, Electric – 19 Miles range - From work to Home, Receive the following errors “Engine Malfunction, Have Vehicle Inspected” and “Hybrid System Malfunction, Have Vehicle Inspected” warning lights come on. Cars behavior – Air conditioning motor running but not cooling air, Loss of power and car very sluggish (have to be careful at intersections), seems to maintain speed even when taking foot of gas and requires extra breaking, seems to be clunky when transmission upshifts/downshifts at times. When leaving work, did not seem to like being in EV mode even though fully charged (Chargers at work) and would switch itself out of that move and say unavailable. Outside air temperature 90 degree (Air Conditioning not working, very uncomfortable). This defect is dangerous and I serious concerns driving this car such as unpredictable loss of power when entering traffic and hesitation / unpredictability when hitting the accelerator. In addition, with the car maintain speed while not touching the gas pedal and requiring extra breaking is a scary. June 13 – Issue cleared and wanting lights were gone before I was able to take it in for service. July 25th – Recurrence of the same issue - Odometer – 8,162, Gas – Full, Electric – 14 Miles range - From work to Home, Receive the following errors “Engine Malfunction, Have Vehicle Inspected” and “Hybrid System Malfunction, Have Vehicle Inspected” warning lights come on. Cars behavior – Air conditioning motor running but not cooling air, Loss of power and car very sluggish (have to be careful at intersections), seems to maintain speed even when taking foot of gas and requires extra breaking, seems to be clunky when transmission upshifts/downshifts at times. When leaving work, did not seem to like being in EV mode even though fully charged (Chargers at work) and would switch itself out of that move and say unavailable. Outside air temperature 87 degree (Air Conditioning not workin

NHTSA ID

11604822

Incident

Jul 25, 2024

On July 15, 2024 this vehicle at 50 mph on cruise control suddenly flashed white warning words indicating problems with the cruise control and immediately thereafter started flashing “hybrid malfunction” and to return to service dealer. At the time of the hybrid malfunction warning which was right after the quick cruise control warning, the engine operation, specifically the gas pedal no longer delivered power to vehicle, either electric or gas. Additional warning was to pull off to the side and stop and turn off vehicle. This occurred and vehicle was pulled to the side put into park and turned off. Waited approximately 3 to 5 minutes and restarted the engine which started in gas with no electric although there was electrical charge on the battery. Was able to continue to our final destination approximately 15 minutes later and no more than 10 miles driven. Hybrid malfunction was still visible on the dash to include the warning stating that vehicle needed to go to the service department. Approximately an hour later, vehicle was turned on again with the same warning about the hybrid malfunction, however, engine started in electric. Drove vehicle to dealership and stated what happened. Dealership the next day stated that this was a phantom code known by Mazda, but no problems associated with the code. Vehicle picked up per service advisors request two days later. Mazda dealership stated that headquarters had eyes on this particular vehicle. A day later after the pick up Mazda dealership requested vehicle be brought back for a “DC box” repair. Dealership stated this process would take a week or thereabouts to replace this component. Vehicle currently in dealership service.

NHTSA ID

11603677

Incident

Jul 15, 2024

I was driving 65 mph and the hybrid system malfunction warning came up. Car dropped to 25mph - pressing the gas pedal would not increase the speed. Continued to coast with no acceleration until it came to a stop and shut off

NHTSA ID

11594863

Incident

May 10, 2024

Driving up snowy pass on I-90 approaching the top of Snoqualmie Pass. Vehicle stalled and warning lights flashed critical warning and loss of power. The vehicle stopped in the middle of the highway and would not start or go into drive. After a few minutes, because of speeding and adverse conditions, another driver collided with my vehicle from behind. Another following vehicle lost control and ran off the road. Nobody was injured. Mazda has not provided any information to what happened with the vehicle. We added about 12k miles in the 5 months of driving it, so we had lots of testing with it, and never ran into this serious of an issue with this or any other vehicle.

NHTSA ID

11583951

Incident

Jan 6, 2024

While connected to a level 2 charger, overheating caused both the charger and charging port of the vehicle to melt together such that it was very difficult to disconnect, and both were then unusable – needing replacement. (photos attached) We feel that there should be some safeguard in the vehicle to prevent this situation as it is a fire hazard. There were no warning lights, sounds, nor signals from the vehicle to warn of the problem. We were present when this occurred, so we could disconnect before a potential fire may have occurred. When we called for service, we had to wait two weeks for an appointment, and then were told that the car was not safe to drive until repaired. This was not considered a warranty item even though the car had fewer than 2800 miles and only owned by us for fewer than 7 months. We were charged $5000 for the charging port and cable assembly and $800 labor. (Copies of service receipts attached.) We contacted Mazda regarding our concern and were given Case #00182286. We received a reply by phone telling us that Mazda bears no responsibility for this (they feel ii was the fault of the charger) and that it is an insurance matter. In fact, auto insurance does NOT cover this. Our concern is that it very well may be a safety issue as people usually charge in their garages or near other cars and buildings in public. In either situation, a fire could be a serious hazard for many people.

NHTSA ID

11578228

Incident

Feb 11, 2024

At 3200 miles the vehicle had a major powertrain malfunction causing the vehicle to throw multiple error codes - Hybrid System Malfunction; Charging System Malfunction; Electrical Leakage Detected. Was instructed to pull over to a safe area immediately. Was unclear how long car would continue to be drivable. Once car stopped it became completely immobile. Repeated restart attempts would not let vehicle start ICE engine or shift into gear. Had to be towed via dollies to nearest dealer for diagnosis and repair. Dealer found a failed PTC heater unit as source of problem and replaced it (Mazda part- KMV6-61-FHX). Vehicle is once again drivable, but the dealer has no idea what would cause the unit to fail and how to avoid future problems. Dealer has heard about this with many vehicles and repaired several similarly. We are fortunate to have found a safe place to pull off the road before powertrain shutdown, but if not we would have been stuck on the road with no ability to move the vehicle and occupants to safety. I hope NHTSA can investigate whether a recall of that part or the software that controls it is needed. NHTSA should also look into the failure mode of the vehicle to see if a different approach is safer and more appropriate.

NHTSA ID

11577948

Incident

Mar 9, 2024

On [XXX], San Diego, CA. (car is new purchase of 1 month 1 week old, 1250 miles, outside temp of 60 degrees, 3/4 battery charge, full tank of gas) Slowed to a stop at a red light in morning rush hour traffic. Engine sputters and multiple warnings appear on dash, including "Hybrid System Malfunction" "I ActiveSense Malfunction" "check engine" etc etc. CAR DIES IN LANE OF TRAFFIC AND LOCKS IN PARK. Attempted to restart 5-6 times, car would start and die immediately with same warnings. 7th restart and engine starts but had to finish drive in sport due to "Hybrid System Malfunction". Per NHTSA and dealer, all previous recalls had been performed/addressed prior to purchase date of [XXX]. Left car with dealer on [XXX] to address and repair issue. Completely unsafe for vehicle to suddenly die in traffic, with no way to move to the side of the road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11576900

Incident

Mar 8, 2024