ON CERTAIN PASSENGER VEHICLES, A CRACK IN THE AIR BAG CRASH ZONE SENSOR HOUSING CAN ALLOW WATER TO ENTER

Sep 24, 2004 — Recall Campaign #04V468000

ON CERTAIN PASSENGER VEHICLES, A CRACK IN THE AIR BAG CRASH ZONE SENSOR HOUSING CAN ALLOW WATER TO ENTER THE SENSOR, CAUSING A SHORT CIRCUIT AND ILLUMINATING THE AIR BAG WARNING LIGHT.

The recall was influenced by the manufacturer with about 42,000 units affected.

See recall notice

NHTSA Safety Recall Notice

04V468000

Manufacturer:	Mazda Motor Corp.
Recall date:	September 24, 2004
NHTSA Campaign #:	04V468000
Units affected:	42,000

Description:: ON CERTAIN PASSENGER VEHICLES, A CRACK IN THE AIR BAG CRASH ZONE SENSOR HOUSING CAN ALLOW WATER TO ENTER THE SENSOR, CAUSING A SHORT CIRCUIT AND ILLUMINATING THE AIR BAG WARNING LIGHT.
Consequeces:: IF THIS PROBLEM EXISTS, THE AIR WILL NOT DEPLOY AS DESIGNED IN CERTAIN TYPES OF FRONTAL CRASHES, INCREASING THE RISK OF DEATH OR SERIOUS INJURY TO THE DRIVER AND FRONT SEAT PASSENGER.
Corrective action:: DEALERS WILL INSPECT THE CRASH ZONE SENSOR AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN ON OCTOBER 28, 2004. OWNERS SHOULD CONTACT MAZDA AT 1-800-222-5500.
Notes:: MAZDA RECALL NO.2304J.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Affects the following:

2004 MAZDA MAZDA3

2004 MAZDA MAZDA3 Complaints
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.;