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Old 11-10-2003, 01:41 AM   #1
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Exclamation Technical Service Bulletins (TSBs) and Recalls for RX-8

List of Mazda RX-8 Technical Service bulletins:
http://www.finishlineperformance.com....php?pageid=11
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Last edited by PoLaK; 03-13-2005 at 12:08 AM.
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Old 12-29-2004, 04:11 PM   #2
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In order to keep the TSB link easily accesible and not buried under hundreds of posts we have split the discussion of the TSBs to a seperate thread. this one will remain locked so no normal replies can be made. Whenever a new TSB is issued a post will be made here to alert you.

TSB Discussion can be found here.
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Old 04-25-2005, 12:38 PM   #3
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Fixed the link - sorry folks!!
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Old 07-15-2005, 11:54 AM   #4
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the Recall bulletins are starting to show up. click the link in the first post. of course you can find them in the recall thread also
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Old 04-05-2006, 01:38 PM   #5
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wow a long time since a TSB for the RX-8. here's the new one
Quote:
TSB: 09-008/06
2006 RX-8 AND MAZDASPEED6 - NAVIGATION SYSTEM DISPLAYS NO MAP OR INCORRECT MAP
APPLICABLE MODEL(S)/VINS

2006 RX-8 and Mazdaspeed6 vehicles equipped with Navigation System
DESCRIPTION

Some vehicles equipped with the factory navigation system that have been activated in one location, then transported long distances with the battery disconnected or room fuse removed, may not display a map or may display an incorrect map.

Customers having this concern should have their vehicle repaired using the following repair procedure.

there is a repair procedure of course but you'll have to wait for Rosenthal to host the PDF

also there is a new Service Tip about rmoving the shifter Panel- seems they have been seen alot of broken tabs Richard must be selling alot of short shift kits
Quote:
TSB: 09-010/06
2004-2006 RX-8 - SHIFT PANEL REMOVAL CAUTION - SERVICE TIP
APPLICABLE MODEL(S)/VINS

2004-2006 RX-8
DESCRIPTION

When removing the shift panel, special attention is required to release the lock(s) attaching the shift panel to the center console. If the lock(s) are broken, the shift panel may not attach properly, causing a poor fitting appearance.

This service tip is being released to identify correct removal points for the shift panel to prevent damage.
again- the full pdf will be available from rosenthal shortly
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Old 04-18-2006, 10:05 PM   #6
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Here's the new PDI step for RX-8s calle FQI - Final Quality Inspection

TSB: 00-001/06
2005-2006 RX-8 - FINAL QUALITY INSPECTION PROGRAM
BULLETIN NOTE

This bulletin supersedes the previous bulletin 00-001/06, issued on 03/08/06. The PART(S) and WARRANTY INFORMATION has been revised.
APPLICABLE MODEL(S)/VINS

2005-2006 RX-8
DESCRIPTION

As a part of our ongoing commitment to product excellence and customer satisfaction, Mazda Motor Corporation has decided to initiate a Final Quality Inspection (FQI) Program. This program consists of an inspection of the vehicle at time of customer delivery.

A critical element of this inspection is replacement of the spark plugs. Repeated short engine cycles encountered during the transportation process and when moved during dealer inventory may prematurely foul the spark plugs. The FQI is not limited to spark plug replacement. However, important inspection items that may require attention from the effects of storage are necessary. (Battery condition, tire pressure etc.…).

Please refer to the inspection procedure for details.
INSPECTION PROCEDURE

1. Verify vehicle has been retailed.

NOTE:

*

Procedure must not be performed more than 3 days prior to vehicle retail delivery.
*

Procedure must be performed within 7 days after vehicle retail delivery.

2. Refer to Final Quality Inspection Form, perform all inspections / procedure as instructed.

NOTE:

*

Make sure to place a copy of the FQI sheet in the glove compartment after performing inspection. Place the FQI tag on vehicle's shifter for 2005 MY. (See 2005 MY note under "PARTS INFORMATION").

BATTERY INSPECTION

NOTE:

*

After wholesale delivery, it is the dealer's responsibility to maintain the condition of the batteries in new Mazda vehicles while in inventory and at the time of new car delivery.
*

This procedure should be performed using a Micro491 battery tester.
*

Battery test results MUST be documented on battery tag.

1. Using the Mazda Micro491 Battery Tester (162-00017), attach the red probe to the positive battery terminal and the black probe to the negative terminal.

NOTE:

*

The tester's display screen will automatically activate for batteries above 1 volt. For batteries that are below 1 volt, it may be necessary to charge the battery for 30 minutes to raise the battery above 1 volt for testing and DTC retrieval.

2. Select "IN-VEHICLE" test by scrolling with the UP and DOWN arrows, then press ENTER.

NOTE:

*

When performing an "In-Vehicle" battery test, make certain that the key is in the OFF position and all electrical accessories and lights are turned off. Be sure that no diagnostic equipment is attached to the vehicle or DLC.

3. Select the correct rating system for the battery by identifying the correct JIS or CCA code.

4. Enter the correct battery rating by using the UP and DOWN arrows to scroll to the correct rating, then press ENTER to start the battery test.

NOTE:

*

For JIS batteries, the tester will only display the first five digits of the six-digit JIS number. Select the JIS number which represents the first five digits of the battery JIS code.

5. The battery tester will display one of the five possible results listed below. Review the results and follow the Action Step for the displayed result.

Battery Tester Display


Action Step

"BATTERY GOOD"


Go to "SPARK PLUG INSTALLATION"

"GOOD - RECHARGE"


Fully charge battery by normal recharging method.

See SLOW CHARGE (REGULAR CHARGE) under "BATTERY CHARGING"

NOTE:

*

If battery tester displays one of the three results listed below, perform a one (1) time quick recharging for 30 minutes. See QUICK CHARGE (BOOST CHARGE) under BATTERY CHARGING. Keep headlights on for 15 seconds to remove surface charge. Turn headlights off and let vehicle sit for 1 minute. Then repeat Steps 1 - 5, retest, then follow the Action Step for the displayed result.


Battery Tester Display


Action Step

"CHARGE & RETEST"


Fully charge battery by normal recharging method one (1) time.

See SLOW CHARGE (REGULAR CHARGE) under "BATTERY CHARGING". Repeat Steps 1 - 5.

NOTE:

*

If same result is displayed on 2nd test attempt, replace battery.

"BAD CELL" Replace Battery

"REPLACE BATTERY" Replace Battery

6. Generate a 6 character DTC code by performing the following steps:

NOTE: These steps are required when submitting a Mazda warranty claim for battery replacement.

1.

Press the "i" icon.
Enter the Warranty RO number by using the UP and DOWN buttons to scroll to the correct character, then press ENTER to select each character.

Enter the RO Line Number by using the UP and DOWN buttons to scroll to the correct character, then press ENTER to select each character.

Press ENTER when complete to view the Warranty Approval Code.

Press ENTER again to view the DTC Code.
7. Attach the printout to the repair order hard copy.

8. To print test results for attachment to RO, perform the following steps:

1.

Turn off the battery tester by disconnecting the battery test leads from the battery.
2.

Align the infrared ports of the battery tester and the printer.
3.

With the tester off, press and hold the print button to activate the OPTION menu.
4.

Use the UP and DOWN arrows to scroll to PRINT RESULTS, then press the ENTER button.

NOTE:

*

The tester will print the results from the last battery test completed.
*

If the tester results do not print, verify that the infrared IR port of the tester is pointing correctly at the infrared IR port of the printer.

9. Write the 6 character DTC code on the RO and attach the printed results to the RO Hardcopy (do not attach with tape due to reaction with the printer paper).

NOTE: Warranty Approval Code and DTC is required for warranty claim submission and must be typed in the Text field of the warranty claim.

10. Perform appropriate repair to vehicle.

11. Verify repair.

BATTERY CHARGING

There are 2 ways to properly charge a battery.

*

Slow Charge (Regular Charge)
*

Quick Charge (Boost Charge)

WARNING:

*

During any battery charge procedure, remove the caps and charge in a well ventilated area. If battery acid comes in contact with your skin, wash away with large amount of water, then go to the doctor immediately.

NOTE:

*

Before disconnecting battery, record radio station presets.

When performing quick or slow charge procedures, make sure the following precautions are adhered to:

*

It is recommended to remove the battery from the vehicle and place battery in a pan of water during charging to avoid the increase of the battery heat.
*

If charging the battery on the vehicle, disconnect the negative battery cable.
*

If equipped, remove the battery caps.
*

When electrolyte liquid level has fallen below the lower level, it can cause the battery to explode. When electrolyte liquid level is below half line of lower and upper level, add electrolyte liquid and fill to the upper level before charging.
*

Avoid the risk of sparks and explosion by connecting up the charger cables before you turn on the charger. If battery cables are connected in reverse order, sparks could appear.
*

Near the end of the charge cycle, hydrogen gas might be produced in large quantities - it has explosive potential so keep all flames away from it. Hydrogen gas can react with the vehicle"s surface, so be sure to wash any possibly affected area with lots of soap and water immediately after you shut the charging down.

SLOW CHARGE (REGULAR CHARGE)

NOTE:

*

You can recover the full charge with a slow charge with 1/10 of the 5 hours ratio capacity.

1. Connect battery charger to battery and adjust current.

2. Charge battery.

3. After completing slow charge, make sure battery has the standard voltage and specific gravity (more than 1.27 for 20°C) and battery has the same voltage and specific gravity 1 hour later.

CAUTION:

*

During slow charge, keep the battery cool (under 45°C (113°F)) as outlined in . If battery gets hotter than 45°C (113°F) (hot to the touch), stop charging temporarily and allow to cool. Resume charging at a decreased current.

QUICK CHARGE (BOOST CHARGE)

WARNING:

*

During any battery charge procedure, remove the caps and charge in a well ventilated area. If battery acid comes in contact with your skin, wash away with large amount of water, then go to the doctor immediately.

NOTE:

*

Quick charge can temporarily recover the battery enough to start the engine but it will not charge the battery completely.

4. Connect the battery charger to the battery and adjust the current.

5. Charge the battery for 30 minutes.

CAUTION:

*

Do not perform quick charge for longer than 30 minutes. The heavy current creates high battery temperature. During quick charge, keep the battery cool (under 55°C (131°F)) as outlined in . If battery gets hotter than 55°C (131°F) (hot to the touch), stop charging temporarily and allow to cool. Resume charging at a decreased current. Do not perform a quick charge on a completely discharge battery as it will damage the battery.

SPARK PLUG INSTALLATION

1. Install spark plugs.

1.

Raise vehicle on hoist.
2.

Remove the driver's side front wheel (spark plugs may be removed with wheel in place, wheel removal provides more working space).
3.

Remove inner splash shield.
4.

Use a ratchet, long extension and spark plug socket to remove / replace spark plugs.

NOTE:

*

Ensure leading / trailing spark plugs are installed in the proper location.

IMPORTANT:

*

Vehicle's original spark plugs will be collected for warranty inspection. Make sure to retain original spark plugs with proper documentation. A warranty parts return request referencing Part Number Main Cause under WARRANTY INFORMATION will be issued.

PART(S) INFORMATION

IMPORTANT: Although the spark plug part numbers are different between 2005 RX-8 (N3Y3-18-S30) and 2006 RX-8 (N3M1-18-1BX), the spark plugs contained in the kits are the same.
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Old 08-27-2006, 10:06 AM   #7
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Voluntary Emissons Recall 4206f

Its "Officially" on folks here are the PDFs.

Its Explained in the Info that some 2006s are included for aDIFFERENT issue. They just threw them in to take care of a glitch while they were adding it instead of having a seperate bulletin/ recall.
Attached Files
File Type: pdf 4206fDealer Letter.pdf (60.0 KB, 3164 views)
File Type: pdf 4206fDealerLetterSubsequent.pdf (30.0 KB, 1767 views)
File Type: pdf 4206fOwnerLetter.pdf (22.9 KB, 2493 views)
File Type: pdf 4206fReimbursementLetter.pdf (47.8 KB, 1358 views)
File Type: pdf 4206fRepairProcedures.pdf (1.79 MB, 2685 views)
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Old 08-27-2006, 10:14 AM   #8
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and of course the warranty extension program

http://www.finishlineperformance.com.../pdf/ad-18.pdf
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Old 02-15-2007, 06:49 PM   #9
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new TSB for the Visor Breaking

Quote:
TSB: 09-002/07
2004-2006 RX-8 - SUNVISOR PIVOT BROKEN
APPLICABLE MODEL(S)/VINS

2004-2005 RX-8

2006 RX-8 with VIN lower than JM1 FE**** ** 207643 (built prior to July 7, 2006)
DESCRIPTION

Some customers may experience the sunvisor broken at the pivot area and the upper and lower parts of sunvisor are split.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Replace the sunvisor with modified part(s). Refer to Workshop Manual section 09-17 SUNVISOR REMOVAL / INSTALLATION.

3. Verify repair.

PART(S) INFORMATION


Part Number


Description


Qty.


Notes

FE01-69-270E-77


Sun Visor (Passenger’s Side)


1


2004-2005

FE01-69-320E-77


Sun Visor (Driver’s Side)


1


2004-2005

FE88-69-270-77


Sun Visor (Passenger’s Side)


1


2006 up to July 7, 2006 production

up to VIN 207643

FE88-69-320-77


Sun Visor (Driver’s Side)


1


2006 up to July 7, 2006 production

up to VIN 207643

WARRANTY INFORMATION

NOTE:

*

This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty term information.
*

Additional diagnostic time cannot be claimed for this repair.



Warranty Type


A

Symptom Code


92

Damage Code


9A

Part Number Main Cause


SEE PART(S) INFORMATION

Quantity


1

Operation Number / Labor Hours:


XXB464RX / 0.2 Hrs. (One or both sides)
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Old 03-17-2008, 10:15 AM   #10
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ok here is the newest lack of power TSB
Attached Files
File Type: pdf 01-014-08-1924.pdf (766.2 KB, 1479 views)
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Re-program your AC Amplifier


Ordered Jan 10th,2003 Picked-up 7/31/03!! 2004 sunlight silver , touring package + 6cd changer. Revi intake and duct, Axial Flow Engineering Short Shifter, Racing Beat Flash!

Quote:
Originally Posted by RX-8NDF
All you have to do is read your owners manual.

Factory Parts & Accessories finishlineperformance.com
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Old 03-18-2008, 11:07 AM   #11
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Msp16
Attached Files
File Type: pdf MSP16.pdf (68.3 KB, 867 views)
__________________
Please read my Winter Thread

Re-program your AC Amplifier


Ordered Jan 10th,2003 Picked-up 7/31/03!! 2004 sunlight silver , touring package + 6cd changer. Revi intake and duct, Axial Flow Engineering Short Shifter, Racing Beat Flash!

Quote:
Originally Posted by RX-8NDF
All you have to do is read your owners manual.

Factory Parts & Accessories finishlineperformance.com
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Old 05-15-2010, 09:28 AM   #12
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TSB 01-050/06

milky dipstick and oil in the intake
Attached Files
File Type: pdf 01-050-06-milky-oil-gauge.pdf (974.0 KB, 650 views)
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Please read my Winter Thread

Re-program your AC Amplifier


Ordered Jan 10th,2003 Picked-up 7/31/03!! 2004 sunlight silver , touring package + 6cd changer. Revi intake and duct, Axial Flow Engineering Short Shifter, Racing Beat Flash!

Quote:
Originally Posted by RX-8NDF
All you have to do is read your owners manual.

Factory Parts & Accessories finishlineperformance.com
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Old 09-07-2010, 09:51 AM   #13
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WOW. Been awhile since there was something to update this thread with.

NHTSA has completed its investigation of the Clutch Pedal Bracket Failure

Quote:
NHTSA Action Number: NHTSA Recall Campaign Number:
PE09045 N/A
Make: MAZDA Model: RX-8
Manufacturer : MAZDA MOTOR CORP
Year : 2004
Component :
POWER TRAIN:CLUTCH ASSEMBLY:PEDAL/LINKAGE
POWER TRAIN:MANUAL TRANSMISSION

Date Investigation Opened : September 23, 2009
Date Investigation Closed : August 19, 2010
Summary:
On September 23, 2009, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation to investigate allegations of the clutch pedal bracket failures in MY 2004 - 2006 Mazda RX8 vehicles. In response to an information request letter sent by ODI, Mazda stated that the failure mechanism may be related to an improper fastener attachment sequence to the body. The improper sequence may create a distortion of the pedal bracket and create a stress amplitude during pedal usage that may go beyond the wear out limit of the bracket. Mazda stated that the percentages of vehicles experiencing the defect is low at approximately 1% of the vehicle population projected to 10 years in service based on analysis of warranty claim data that best represented the alleged defect. In terms of risk to motor vehicle safety, Mazda stated that the failure is progressive with warning manifested in noise and difficulty in shifting gears prior to complete failure of the bracket. Mazda also stated that when a bracket fracture occurs the clutch pedal may lean towards the brake pedal however gear shifting becomes impossible prior to any contact of the clutch pedal to the brake pedal. ODI is not aware of any crashes associated with a clutch pedal bracket failure in the subject vehicles. ODI's analysis of warranty claim data provided by Mazda yielded failure rates of approximately 3% projected over 10 years in service. ODI's analysis of Vehicle Owner Questionnaire (VOQ) data complaint indicates that approximately 5% of the VOQ complainants allege they were unable to get out of the roadway as a result of a clutch pedal bracket failure. None of these incidents occurred on a highway. Approximately 7% of the complainants alleged a contact condition after a clutch pedal bracket failure of the clutch pedal to the brake pedal. None of these complaints noted difficulty in getting the vehicle stopped.

Mazda has informed ODI that it will conducted an Owner Notification of an extended warranty coverage program increasing the clutch pedal assembly warranty to 8 years and limited at 100K miles for model years 2004 through 2009 RX8 vehicles. A safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted. Accordingly, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency will continue to monitor this issue and will take further action if warranted by the circumstances.
Mazda thought the problem happened in about 1% of cars. NHTSA investigation foudn it in about 3% statistically. Mazda has extened the warranty for the clutch pedal for 04-09 cars to 8 years.

Letters will be going out to all owners of record. If you bought yours used you might want to get to a dealer and make sure you are the owner of record in Mazda's system.
Attached Files
File Type: pdf NHTSA ODI - Defects.pdf (99.0 KB, 366 views)
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Re-program your AC Amplifier


Ordered Jan 10th,2003 Picked-up 7/31/03!! 2004 sunlight silver , touring package + 6cd changer. Revi intake and duct, Axial Flow Engineering Short Shifter, Racing Beat Flash!

Quote:
Originally Posted by RX-8NDF
All you have to do is read your owners manual.

Factory Parts & Accessories finishlineperformance.com
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Old 09-07-2010, 09:51 AM
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