2004 Mazda Mazda3

This model car has a fuse box under the glove box known as a "passenger junction box" that has a faulty or defective relay soldered onto the circuit board. The relay is tied to lighting that includes the interior lights, exterior front parking lights, exterior rear tail lights, and the license plate light and is controlled by the left turn signal stalk (rotating switch). Based on my experience and many others (on the Mazda 3 forums), this relay has the tendency to fail and cause all of these lights tied to this relay to intermittently or permanently be disabled. There is no warning for this; the driver will only notice when driving at night that the interior illumination of the dashboard goes completely dark, which could cause disorientation and confusion as to whether or not the car is operable. Subsequently, the problem can be recreated by attempting to turn the lights on and off and there will be no response (and no clicking noise...it is audible when working and it switches on); the relay fails to operate and all the lights will not turn on. Driving at night without tail lights is extremely dangerous and I am surprised this has not caused serious injury from rear-ending incidents in nighttime or inclement weather situations. The serial/model number of junction box on my vehicle is BN8B-66730-C and many others on the forums have had the same issue with the same model, as well as other variations of the box. Some on the forums went as far as replacing the culprit relay (see attachment); however, at the risk of destroying the entire junction box and rendering the vehicle unusable. I finally ended up purchasing a replacement unit on eBay which corrected the issue so far and has made the lights reliable again.

NHTSA ID

11609269

Incident

Aug 1, 2021

The contact owns a 2004 Mazda 3 equipped with Hankook Tires, Tire Line: Ventus S1 Noble2, Tire Size: 205/50/R17, DOT Number: N/A. The contact stated that while driving at approximately 45 MPH, a loud explosion was heard. The contact's wife alerted him that the rear driver's side tire had blown out. The contact's vehicle was then rear-ended by another vehicle, causing his vehicle to turn 360 degrees. The air bags did not deploy. The contact was not injured, but his wife suffered from neck pain. Medical attention was not received. A police report was filed. The vehicle was towed to the contact's workplace and was not deemed totaled by the insurance company. A body shop repaired the vehicle. The tire manufacturer was made aware of the failure and informed the contact to send in the faulty tire. The tire failure mileage was unknown. The vehicle failure mileage was 150,000.

NHTSA ID

11561370

Incident

Apr 1, 2023

Mileage

150,000 mi

There has been no accident- the vehicle is my mother in laws vehicle- my concern is while at work she has at times loaded our daughter into the vehicle- I inspected the vehicle one day while as an employee of Les Schwab- the driver cvc axle vibrates so bad from the boot being torn and having no lubrication- these axles power the vehicle forward and if not maintained can snap and cause damage- the wipers no longer work correctly- the tires are 2017 and old and weather cracked- potential to separate while driving or blow out on the heated pavement. upon inspection also found that the front shocks are blown out and bouncing in the mounts under the hood- causing the tires to not have the correct contact patch on the road thus decreasing traction and control- on top of all this the vehicle hasn't been registered since 2020 and has no insurance on the vehicle- again there has been no accident...yet- this is my concern- that if this vehicle continues to remain operational and on the road it not only puts the driver and occupants at risk but also other drivers- kids- teens and anyone that may be on the other end o the crash when the vehicle does snap the cvc axle or blow i out a tire

NHTSA ID

11538237

Incident

Aug 13, 2023

The contact owns a 2004 Mazda Mazda3. The contact stated that while starting the vehicle and driving at an undisclosed speed, the air bag warning light was illuminated. The dealer was made aware of the failure but informed the contact that the VIN was not included in a recall. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure and confirmed that the VIN was not included in a recall. The contact related the failure to NHTSA Campaign Number: 04V468000 (Air Bags). The failure mileage was approximately 165,000.

NHTSA ID

11438521

Incident

Oct 28, 2016

Mileage

165,000 mi

THE CAR RAN GREAT FOR THE END OF 2019. I BOUGHT IT USED AT 145,000 MILES. THEN THE AUTOMATIC TRANSMISSION STARTED TO SLIP. NOW ITS STUCK IN LIMP MODE.

NHTSA ID

11318945

Incident

Jan 1, 2020

Mileage

45 mi

THE TAIL LIGHTS GO OUT INTERMITTENTLY DUE TO A DEFECTIVE PASSENGER JUNCTION BOX (FUSE BOX). TAPPING THE BOX WITH A SCREWDRIVER HANDLE WILL BRING THE TAIL LIGHTS BACK ON FOR A WHILE. THIS HAS BEEN A MAZDA 3 ISSUE OVER THE YEARS. THE SHOULD BE A RECALL ON THIS.

NHTSA ID

11279063

Incident

Aug 7, 2018

Mileage

204,000 mi

TL* THE CONTACT OWNS A 2004 MAZDA 3. THE CONTACT STATED THAT THE AIR BAG WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS DIAGNOSED BY AN INDEPENDENT MECHANIC WHO STATED THAT THE FRONT PASSENGER SEAT MAIN MODULE NEEDED TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED. AN UNKNOWN DEALER WAS CONTACTED, BUT COULD NOT ASSIST. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 128,680.

NHTSA ID

11206320

Incident

May 1, 2018

Mileage

128,680 mi

THE LOCK RELEASE LEVER ON THE STEERING WHEEL GET LOOSE WHILE THE VEHICLE IS IN MOTION AND DOES NOT LOCKED IN PLACE. THIS CAN CAUSE AN ACCIDENT AND SERIOUS INJURIES. THERE SHOULD BE A RECALL TO GET THIS REPAIR.

NHTSA ID

11054858

Incident

Jan 8, 2013

This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted in Red text. 09-042/04 12/10/04 DESCRIPTION Some vehicles may exhibit inoperative electric rear window defroster grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass. Follow the diagnostic and repair procedures included in this service information to inspect and service rear defroster grid lines, integral antenna concerns or broken terminal tabs.

This Service Alert supersedes the previously issued SA listed below: The changes are noted in Red. SA-011/24 02/12/24, 06/06/24, 07/29/24 DESCRIPTION Mazda has developed factory recommended scheduled maintenance services that support all major vehicle systems. Mazda recommends dealers follow the scheduled maintenance tables as cited in the vehicle-specific workshop manual or owner's manual. Services performed outside of Mazda's factory scheduled maintenance are not recommended. These services are unnecessary and create unneeded expenses for your customers. SCHEDULED MAINTENANCE Refer to the applicable Workshop Manual or Owner's Manual for vehicle -specific manufacturer scheduled maintenance. Workshop Manual - Refer to section 00-00 SCHEDULED MAINTENANCE. Owner's Manual - Refer to section 8 Maintenance and Care. b. Note: Please refer to the information below outlining the services not included in Mazda's Factory Scheduled Maintenance: IMPORTANT: Recommending fluid flushes when not necessary can lead to customer confusion and dissatisfaction. Fluid flushing for preventive maintenance purposes is strongly discouraged, unless otherwise specified in a published procedure (Owner’s Manual, Workshop Manual, Technical Service Bulletin, etc.).

A musty/mildew type odor may come from the vents when the air conditioning (A/C) system is operating. It is most noticeable when the A/C is first turned ON. This odor is the result of mold growth in the A/C evaporator/cooling unit which is caused by condensation, dust, and pollen within the cooling unit. This condition is usually worse during high humidity conditions. “Mazda Air Cooling Coil Coating” is available to encapsulate the mold to reduce odors. If the product is properly applied, it can effectively reduce the musty/mildew odor for up to three years. NOTE: See parts information for Mazda Air Cooling Coil Coating and Kit part numbers.

Some vehicles may experience exterior trim heat damage such (melted, separating, etc.) when parked near a glass building or Low-E windows. This may be caused by the sun's reflection. If a structure's windows create enough of a curve, the concave glass can focus the sun's rays onto a small area and acting like magnifiying glass direct the sunbeams into a hot pinpoint of light. This magnifcation of the sun's rays can cause damage to vehicle trim (see examples). Additional information and exemplar images regarding this phenomenon can be found by performing a google search.

Some customers may complain about a noisy HVAC blower motor or odor after a cabin air filter replacement. Foreign debris on the blower motor after servicing the cabin air filter may be the cause. During the removal of the cabin air filter, foreign debris (leaves, dust, dirt....ect.) may fall on the blower motor causing a fluttering type noise or odor.

A musty/mildew type odor may come from the vents when the air conditioning (A/C) system is operating. It is most noticeable when the A/C is first turned ON. This odor is the result of mold growth in the A/C evaporator/cooling unit which is caused by condensation, dust, and pollen within the cooling unit. This condition is usually worse during high humidity conditions. “Mazda Air Cooling Coil Coating” is available to encapsulate the mold to reduce odors. If the product is properly applied, it can effectively reduce the musty/mildew odor for up to three years.