2009 Mazda Mazda6 Suspension Problems

Component or System that Failed: The front subframe on my 2009 Mazda 6i Touring is completely rusted through. There are holes in the frame and large flakes of rusted metal breaking off. The car is available for inspection if needed. Safety Risk: This is a serious safety concern because if the subframe fails, I could lose steering or suspension control while driving. That would put me and other drivers at immediate risk of an accident. Reproduction / Confirmation: An independent mechanic confirmed the problem and told me the car is unsafe to drive in its current condition. Inspection: The vehicle had the original Mazda subframe corrosion recall performed years ago, but now the same exact problem has come back. The car has not yet been re-inspected by Mazda, but the severity of the rust is obvious. Warning Lamps / Symptoms: There were no warning lights or messages before this happened. The issue was only noticed when the rust and holes became visible on the underside of the car during a recent inspection.

Hello, My name is [XXX] . I took our Mazda 6 in for wheel balance and alignment and was informed of very serious rust issues in the rear suspension. I was pretty shocked at what they showed me. I worked at Raben Tire for 10 years and I've never seen anything like this. I have two retired mechanic friends look at it, and they (along with the mechanic from firestone) said they cannot even fathom how this level of rust is possible (80+% of the miles on this vehicle are highway). One of my retired mechanic friends started looking into it and said he'd noticed the 09 Mazda recalls for suspension rust. We all thought that made sense given how immensely abnormal this rusting is. The recall list sent to me says "front" suspension. I'm not sure why the front is listed and not the rear, but this, to all of us, is very clearly faulty (the rusting is INCREDIBLY abnormal) and we believe should be considered as part of the suspension rust recall (there are no rusting issues anywhere else). Ive provided pictures. This is incredibly unsafe. The rear suspension could collapse at any moment while driving and cause casualties. Thank you for your time, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The front and rear crossmembers have significant rust. The front has holes and chunks of metal missing due to rust corrosion. The rear has flaking and is deeply pockmarked with rust. These are structural components. Failure can lead to a crash.

The rear Suspension Frame has failed due to corrosion. The right rear tire has worn severely from the premature failure of that part on the right side. I feel it was a defect in Engineering by Mazda. My email: [XXX] Mobile: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Rear suspension cross-member corroded to the point that a minor pothole separated the right lower control arm mounting point from the cross-member, rendering the car undrivable. The rest of the car is fairly rust-free.

The rear frame has failed due to corrosion on the right side. The rear passenger tire is canted in on the topside worn severely worn. This was noted when I drove home from my job. This is a critical part of the vehicle and should've never failed. I'm hopeful to hear from the NHTSB for a repair to be done properly by Mazda;

Rear subframe corrosion

2009 Mazda 6 Rear subframe and springs are deemed unsafe due to extreme rusting and corrosion. The vehicle is registered and has been registered in both NY and PA (salt states), however was regularly washed and garage maintained. Vehicle will no longer pass inspection due to this issue and Mazda indicates no recall for the rear at this time and is ignoring that this is a highly prevalent issue. Mazda recalled and acknowledged this issue on these makes/models related to the front; however refuses to acknowledge and repair/recall the issue extending to the rear. The vehicle is in otherwise good shape, and the extreme rusting to the subframe/springs is not consistent with normal wear and tear. This is an extremely prevalent issue arising to these vehicles being ignored by Mazda. Mechanics are indicating the issue is extremely deteriorated and not safe, but that the vehicle is in otherwise good shape and the issue is consistent with faulty parts.

I noticed a rattling sound that seemed to come from the rear passenger side wheel. I took it to a mechanic who told me that the rear sub-frame was so rusted that the damper had come loose from the sub-frame and caused the rattling sound. He said that he was unable to reattch the damper because the sub-frame was too rusted. The only solution was to remove the loose damper to eliminate the rattling sound and continue driving that way OR have the rear sub-frame replaced which would cost from $4,000-$6,000.

This 2009 Mazda 6 hit a chuck hole in the Buffalo NY area, virtually severing the connection between the rear cross member (aka cradle or sub frame) and the right rear wheel and rendering the car all but undriveable. Mechanic said the failure to sufficiently rust proof the subject parts caused severe deterioration of the rear sub frame. This is essentially the same problem that led NHTSA to issue a recall on this vehicle for the front engine cradle in 2018.

"What component or system failed or malfunctioned, and is it available for inspection upon request?" - Rear subframe. Total rust through due to improper steel alloy and insufficient paint. Same as happened for the front subframe. Front subframe was recalled as 2818I (Mazda's number) and 19V-323, 18V-631 (NHTSA numbers). NHTSA should also mandate rear subframe be recalled. "How was your safety or the safety of others put at risk?" - Total catastrophic structural failure of rear suspension. Would result in a total loss of control while driving. This would likely lead to a severe, possibly fatal accident at-speed. "Has the problem been reproduced or confirmed by a dealer or independent service center?" - As reported by independent service center. "Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others?" - no, this exact vehicle has not been inspected by manufacturer. Manufacturer is doubtless aware of the issue. A cursory google search leads to dozens of identical cases. "Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear?" - there were no warnings of the failure prior to discovery by service center.

I took my car to the mechanic for some routine maintenance and they called to tell me they discovered that the rear subframe is completely corroded. They say the car is not safe to drive, as it could come apart at any moment, and it will cost so much to repair (current estimate is $8000 and still climbing!) that it may be better for me to buy a new car (which I cannot afford). The mechanic expressed shock at how badly the subframe has deteriorated. He said it is in much worse shape than the rest of the car, which I have always maintained carefully. In 2019 my car was recalled for a defective front cross-member, which the dealer replaced. I was told at the time that it was recalled because the coating applied to it was defective and did not protect the part from corrosion. Based on my research, it seems that the same defective coating was applied to the rear subframe, and that it is why it has rusted so quickly and severely. I see that the NHTSA is already aware of this issue - [XXX] . The exact problem I am having is described in [XXX] : "Mazda6 owners told NHTSA there was severe corrosion of the right rear subframes that caused the steering rack mounting bolts to fail." It is completely unacceptable that Mazda replaced the defective part in the front but has not replaced the similarly defective part in the rear, which has failed for the same reason. I am furious that this has made my beloved car, which is otherwise in very good shape and runs beautifully, undriveable. Mazda should be required to repair this severe safety defect, which is entirely their responsibility! Thank you for your time. I look forward to hearing from you at your earliest convenience. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Both my back and front chassis are completely rusted through and it’s a complete screwed car. Looking online there is a recall on something like this but not for my model? All I see online is people talking about how they had to scrap their cars because of this issue. The salt and snow has ruined this car and so many people have complained to no avail.

The contact owns a 2009 Mazda Mazda6. The contact stated the vehicle was taken to an independent mechanic for the replacement of the headlights, and the mechanic discovered that the rear suspension was rusted and corroded while the vehicle was on the lift. Additionally, the passenger’s side rear spring was detached. The mechanic advised the contact that the vehicle was unsafe to drive. The rear suspension needed to be replaced; however, the vehicle was not repaired. The manufacturer was notified of the failure and stated that the vehicle was not included in a rear suspension recall for corrosion and a case was not opened with the manufacturer. The approximate failure mileage was 138,000.

I brought my 2009 Mazda 6 to the dealership to inspect the suspension after the car began pulling to the right when braking. I was informed the front and rear subframes have failed on this car due to corrosion—even though the front subframe was serviced previously for the recall campaign with the addition of a support bracket. The front subframe will be replaced by Mazda due to the failed recall repair. However, Mazda will not cover the rear subframe at this time because it has not been recalled. The dealership recommends I do not drive the car until the rear subframe is replaced. However, the dealership quoted over $5,000 to replace it due to the high price of the subframe. There is a significant risk the lower control arms can separate from the vehicle due to corrosion, resulting in loss of vehicle control.

Purchased the 2009 mazda6 for our daughter. Brought it to our mechanic for an electrical issue. We were told that the rear subframe was completely rusted and that the vehicle was unsafe to drive.

the front crossmember rusted out and broke while driving down the road (per owner), all bolts needed replaced along with the rear engine torque strut mount. Confirmed and replaced by an independent shop 01/20/2024. upon inspection the rear crossmember, lower control arms, bolts, and other parts are all rusted and ready to break at anytime. front crossmember is at the shop for inspection. Car can easily be at shop on a lift for inspection. No warnings.

The REAR subframe has rusted out pretty much completely, but the total failure of the right rear spring mount has allowed the spring to punch through the frame, being stopped only by the top plate which has now turned sideways and is lodged between the spring and the floor pan. I understand this is a common problem with this and a few other model years, and has not been addressed by Mazda. I am hoping to help change this.

Purchased the vehicle, brought it to our mechanic. Was told that the rear subframe was completely rusted, making it unsafe to drive.

There was a recall on the front subframe due to rust. The rear subframe has the same safety issue but there is no recall for that and there should be