— Mazda is recalling nearly 105,000 RX-8 cars in two U.S. recalls, both to fix defects that can cause serious problems for drivers, occupants and property.
2004-2008 Mazda RX-8 Recall
The largest recall includes about 69,450 model year 2004-2008 Mazda RX-8 cars to fix gas leaks that can cause the cars to burn. The automaker says the main fuel pump pipe can crack due to heat from the engine and the exhaust. That crack will allow gas to leak, and from there any ignition source will be enough to send the car up in flames.
Mazda says the fuel pump module has a weak fuel pump pipe that can deteriorate by the heat from the engine and exhaust pipe. A saddle-type gas tank is used with two pumps with one used as the main fuel pump and the other for fuel transfer from the sub-tank. The main fuel pump is one with the problems.
Mazda learned of problems back in November 2007 when it received a report and opened an investigation. Engineers found a weld line was formed on the fuel pump pipe during manufacturing and a crack had occurred at the weld line. However, Mazda couldn't determine what caused the failure, so in 2008 engineers were considering increasing the thickness of the pipe to prevent the weld line from forming.
Finally the automaker discovered the effect heat was having on the pipes even if a tiny crack was there from the beginning. Once the pipes were thickened the cracks didn't occur at nearly the frequency as before, so the investigation was closed.
Then November 2016 arrived when Mazda received a report from Japan about a fuel leak connected to a Japanese recall, so another investigation was opened. Engineers collected the parts and found the same cracked pipes as before.
Following that was another report that arrived from the U.S. about the same gas leak problem, causing Mazda to order the recall.
Mazda had recalled the cars in 2016 in the U.S. under a recall that Mazda called "RX-8 Fuel Pump Sealing Rings May Leak Fuel," but obviously the fix didn't work because the automaker targeted the seals instead of the fuel pump pipes.
All the recalled 2004-2008 Mazda RX-8 cars were manufactured from April 10, 2003, through February 18, 2008.
The recall should begin July 30, 2017, when Mazda dealers will start replacing the fuel pump filter kits.
If you own a 2004-2008 Mazda RX-8 and have questions, call 800-222-5500 and ask about recall number 1017E.
2004 Mazda RX-8 Recall
In the second and smaller recall, the 2004 Mazda RX-8 has serious problems that can cause a driver to lose control of the car.
More than 34,300 cars have ball joint sockets on the front suspension lower control arms that can crack, causing the ball joints to separate from the sockets.
Mazda says there was a faulty caulking process used for the ball joints that can cause the ball joint sockets to crack. The ball joint can separate and make the car nearly impossible to control if a large load is applied on the suspension while driving.
The automaker says the recalled 2004 RX-8 cars were built April 10, 2003, through May 6, 2004.
The recall is scheduled to begin July 30, 2017. Mazda dealers will need to replace the front lower control arms, but until then, owners with questions should call 800-222-5500. Mazda's number for this RX-8 recall is 1117E.
CarComplaints.com has complaints from owners about the Mazda cars named in the recall: