NHTSA ID Number: 10043728
Manufacturer Communication Number: SSP-89
TSB/Document Date: 2012-04-24
Summary
MAZDA
: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. SMALL CRACKS MAY OCCUR AT RUBBER BUTTON OF FRONT DOOR HANDLE REQUEST SWITCH, ALLOWING MOISTURE TO ENTER AND CAUSING A MALFUNCTION OF ADVANCED KEYLESS ENTRY SYSTEM TO AFFECT DOOR LOCK/UNLOCK FEATURES. *PE UPDATED 12/18/12. *PE
SB-10043728-2023
TO:
Mazda Dealership General Managers, Service Managers, and Parts Managers
DATE:
February 2012
SUBJECT:
2009 Mazda6 Advanced Keyless Entry Door Handle Request Switch
Special Service Program (SSP) 89
Mazda Motor Corporation has decided to conduct a Special Service Program (SSP) on certain
2009 Mazda6 vehicles equipped with Advanced Keyless Entry and produced from February 4,
2008 through February 27, 2009.
On certain 2009 Mazda6 vehicles equipped with the Advanced Keyless Entry system, small
cracks may occur over time at the rubber button of the front door handle request switch(es). If
moisture enters the switch, it could cause the vehicle’s advanced keyless entry system to
malfunction, affecting the door lock/unlock features. This could also illuminate the dash warning
lights, and in some cases, it may affect the push button start/stop features. Dealers should
replace the rubber button in the request switch on both front doors. In some cases, the request
switch may also require replacement. Please refer to Attachment II for repair details.
Owners of subject vehicles will be notified by first class mail beginning February 6, 2012.
This package contains important information about SSP 89:
Attachment I
Attachment II
Attachment III
Parts and Service Information
Repair Procedure
Owner Notification Letter
For technical assistance, call the Technical Assistance Hotline at (888) 832-8477, Option 3 for
English speaking Hotline Specialist, option 4 for Spanish speaking Hotline Specialist.
For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626, option 2.
For warranty questions, contact the Warranty Hotline at (877) 727-6626, option 3.
Please make certain that the appropriate personnel in your dealership are aware of these
resources and are familiar with the details of this program before responding to customer
inquiries. Your understanding and support in carrying out this program is greatly appreciated.
Sincerely,
Kiyoshi Yagi
Director, Technical Services
Mazda North American Operations
Mazda North American Operations
Technical Services Division
1444 McGaw Ave.
Irvine, CA 92614-5570
www.MazdaUSA.com
ATTACHMENT I – PARTS AND SERVICE INFORMATION
SSP89
CONDITION OF CONCERN
On certain 2009 Mazda6 vehicles equipped with the Advanced Keyless Entry system, small
cracks may occur over time at the rubber button of the front door handle request switch(es). If
moisture enters the switch, it could cause the vehicle’s advanced keyless entry system to
malfunction, affecting the door lock/unlock features. This could also illuminate the dash warning
lights, and in some cases, it may affect the push button start/stop features. Dealers should
replace the rubber button in the request switch on both front doors. In some cases, the request
switch may also require replacement. Please refer to Attachment II for repair details.
SUBJECT VEHICLES
Model
2009 MY
Mazda6
VIN range
Production Date Range
From February 4, 2008 through
February 27, 2009
1YVHP82***95M00001 through
1YVHP82***95M51929
Note: The asterisk symbol “*” can be any letter or number.
OWNER NOTIFICATION
Mazda will notify U.S. owners by first class mail beginning February 6, 2012. Owners will be
advised they should bring their vehicle in to have the dealer repair the front door request
switches.
PARTS INFORMATION
Description
Part Number
Button Kit
GSY2-58-4BY
Switch Kit
Campaign Label
GSY1-58-4BY
9999-95-065A-06
Quantity
=
1 2 buttons,
2 screws & 2 pads
1
1 = 50 labels
Note
Replace in both front doors
As needed upon inspection
Obtain in MStore (no charge)
WARRANTY CLAIM PROCESSING INFORMATION
Rubber Button Replacement
Warranty Type Code
Process Number
Symptom Code
Damage Code
Part Number Main
Cause / Quantity
Labor Operation /
Labor Hours
A
J1201A
99
99
GSY2-58-4BY / 1
LH
YY735ARX / 0.3 hrs.
RH
YY735BRX / 0.3 hrs.
Both Sides
YY735CRX / 0.5
Page 1 of 2
ATTACHMENT I – PARTS AND SERVICE INFORMATION
SSP89
Switch Replacement
Warranty Type Code
Process Number
Symptom Code
Damage Code
Part Number Main
Cause / Quantity
Labor Operation /
Labor Hours
A
J1201B
99
99
GSY1-58-4BY / 1-2
LH
YY736ARX / 0.7 hrs.
RH
YY736BRX / 0.7 hrs.
Both Sides
YY736CRX / 1.3
VERIFY THE VEHICLE IS APPLICABLE TO SSP89
1. Verify the vehicle is within the following range:
Model
2009 MY
Mazda6
VIN range
Production Date Range
1YVHP82***95M00001 through
1YVHP82***95M51929
From February 4, 2008 through
February 27, 2009
If the vehicle is within the above range, go to step 2.
If the vehicle is not within the above range, it is not applicable to the SSP89.
2. Perform a Warranty Vehicle Inquiry using your eMDCS System.
eMDCS System - Vehicle Status Inquiry Results
If eMDCS displays:
SSP89 OPEN
Campaign Label is:
Present
Not present
Present
SSP89 CLOSED
SSP89 is not
displayed
Not present
Does not apply
Action to perform:
Contact the Warranty Hotline at (877)
727-6626, option 3, to update vehicle
history
Proceed to “REPAIR PROCEDURE”.
Return vehicle to inventory or customer.
Complete a campaign label and apply to
vehicle's hood or bulkhead.
SSP89 does not apply to this vehicle.
Return vehicle to inventory or customer.
REPAIR PROCEDURE
Please refer to Attachment II.
Page 2 of 2
2009 MAZDA6 ADVANCED KEYLESS ENTRY DOOR HANDLE REQUEST SWITCH
ATTACHMENT II
SSP89
SSP89/RECALL TEMPLATE
2009 Mazda6 Advanced Keyless Entry Door Handle Request Switch SSP89
A. OVERVIEW
Some vehicles may experience water entry through a crack in front door handle request switch. This condition
may result in the keyless unit intermittently freezing.
Customers may experience some (or all) of the conditions below:
• ABS warning light, DSC indicator light, DSC OFF indicator light and keyless indicator light (red) suddenly illuminate while driving.
• Information display and navigation display (if equipped) are temporarily blacked-out.
• Unable to start / stop the engine with the push button start.
B. VEHICLE INSPECTION PROCEDURE
1. Verify that the vehicle is within the following ranges:
-
Model
VIN Range
Production Date Range
2009 Mazda6
1YVHP82***95M00001 through
1YVHP82***95M51929
From February 4, 2008 through
February 27, 2009
If the vehicle is within the above range, proceed to step 2.
If the vehicle is not within the above range, return the vehicle to the customer or inventory.
Page 1 of 19
ATTACHMENT II
SSP89
2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for a Campaign Label
SSP89 attached to the vehicle’s hood or bulkhead. Refer to eMDCS System - Warranty Vehicle Inquiry
Results table below.
NOTE: Verify SSP89 number as the vehicle may have multiple SSPs.
CAMPAIGN
LABEL
CAMPAIGN LABEL
CAMPAIGN NO:_____________
DEALER CODE:_____________
DATE:
P/N 9999-95-065A-06
campaign_label
CAMPAIGN
LABEL
1326b
eMDCS System - Warranty Vehicle Inquiry Results
If eMDCS displays:
Campaign Label is:
Action to perform:
Present
Contact the Mazda Warranty Hotline at (877) 7276626, Option 3, to update vehicle history.
Not present
Proceed to “C. OUTER DOOR HANDLE ADVANCED
KEYLESS ENTRY REQUEST SWITCH BUTTON
REPLACEMENT AND SWITCH INSPECTION PROCEDURE”.
Present
Return vehicle to inventory or customer.
SSP89 CLOSED
Not present
Proceed to “F. CAMPAIGN LABEL INSTALLATION”.
Complete a label and apply to vehicle’s hood or bulkhead.
SSP89 is not displayed
Does not apply
SSP89 does not apply to this vehicle. Return vehicle
to inventory or customer.
SSP89 OPEN
Page 2 of 19
ATTACHMENT II
SSP89
C. OUTER DOOR HANDLE ADVANCED KEYLESS ENTRY REQUEST SWITCH BUTTON REPLACEMENT
AND SWITCH INSPECTION PROCEDURE
1. Remove fuse cover and pull the power door lock fuse.
2. Separate the auxiliary key from the key fob and install the key into the door lock.
Page 3 of 19
ATTACHMENT II
SSP89
3. Using the fiber stick remove the door handle cap access hole cover.
4. Cut off approximately 12 inches of mechanics wire and bend as shown below. This wire will be used to hold
the lock rod in place and to assist during reassembly.
Not to scale
Page 4 of 19
ATTACHMENT II
SSP89
5. Turn the key counter clockwise, hook in the mechanics wire around the lock rod (B), then push the hook
down the rod approximately 3 inches (A), and bend the wire down (C) at the access hole as shown below,
then release the key.
6. Using the small pick release the lock rod clip (A).
7. Loosen the silver T25 torx screw (B) making sure it is completely loose.
NOTE: The torx screw (B) will be retained by the tabs and cannot be removed.
8. Reach in with the small screw driver or pick and press down on the lock tab (C) and remove the handle end
cap and lock cylinder.
Page 5 of 19
ATTACHMENT II
SSP89
9. Grasp the outer handle and quickly pull towards the back of the door.
10. Pull the handle out of the door far enough to get access to the back side of the handle, and remove the foam
pad (A) and lift the rubber screw cover (B) off of the back of the handle.
Page 6 of 19
ATTACHMENT II
SSP89
11. Using the T10 torx driver remove the 3 screws (A).
12. Using the fiber stick carefully pry the colored cover off of the door handle.
NOTE: The cover is hooked in at the harness end, so start at the button end and work your way back.
Page 7 of 19
ATTACHMENT II
SSP89
13. Remove the rubber button and closely inspect for cracks. If cracks are found, closely inspect the switch (B)
and switch cavity (A) for signs of corrosion or moisture.
Example of corrosion include: Greenish residue (A) on the switch and/or on the bottom of the switch cavity.
• Was Corrosion found on the switch or switch cavity?
• No, proceed to D. RUBBER BUTTON REPLACEMENT AND HANDLE REASSEMBLY.
• Yes, proceed to E. REQUEST SWITCH REPLACEMENT PROCEDURE.
Page 8 of 19
ATTACHMENT II
SSP89
D. RUBBER BUTTON REPLACEMENT AND HANDLE REASSEMBLY
1. Install new rubber button, making sure rubber button is in proper alignment with the three switch tabs.
Page 9 of 19
ATTACHMENT II
SSP89
2. Confirm correct position of the switch wires and switch, then align the colored outer handle with the hook (B)
at the harness end then move the cover down into position with the rubber button and snap into place.
CAUTION:Prior to reinstalling the cover make sure the switch wires are positioned correctly at the rear
screw hole location (A).
Page 10 of 19
ATTACHMENT II
SSP89
3. Install the three screws.
4. Reinstall the rubber screw cover at the harness end making sure the rubber cover in positioned under the
tab (A) as shown below.
5. Install new foam pad at the switch end of the handle.
Page 11 of 19
ATTACHMENT II
SSP89
6. Reinstall the door handle into the door and end cap/key cylinder assembly.
7. Tighten the silver T25 torx screw.
8. (Drivers Side Only) Using the mechanics wire and auxiliary key, turn the key cylinder, manipulate the lock
rod back into the clip, then reposition the lock rod clip over the lock rod.
9. Reinstall the plastic hole cover and move to the passenger side of the vehicle.
10. Repeat rubber button inspection procedure for the passenger side outer door handle, starting at step seven
after removing the plastic hole cover.
11. Reinstall the fuse and cover.
12. Verify that the Advanced Keyless Entry system operates properly.
Page 12 of 19
ATTACHMENT II
SSP89
E. REQUEST SWITCH REPLACEMENT PROCEDURE
Special Service Tool (SST) Removal Set (part number 49D0-66-004)
A
Terminal Lock (Cover) Remover
B
Terminal Lock Release Tool
1. Completely remove the outer handle according to Workshop Manual “FRONT OUTER HANDLE REMOVAL
/ INSTALLATION”.
NOTE: Remove the mechanics wire from the lock rod of the key cylinder (Drivers side only).
2. Remove the terminal lock (A) from the connector housing using SST Removal Set 49D0-66-004 (B).
Page 13 of 19
ATTACHMENT II
SSP89
A
Tool Slot
A
Connector Housing
B
Terminal Lock (Cover)
C
Tool
Page 14 of 19
ATTACHMENT II
SSP89
3. Remove the request switch terminals from connector housing using terminal lock release SST.
A
Terminal Lock Release Tool
B
Blue Wires
Cutaway view of connector lock and tool (lock tab is part of the connector, not the terminal)
A
Terminal Lock Release Tool
B
Terminal Lock
Page 15 of 19
ATTACHMENT II
SSP89
4. Remove and discard the double-sided tape then remove then request switch.
5. Position new request switch into handle body align wires and install new double-sided tape as illustrated
below.
6. Insert the request switch terminals into to the connector.
CAUTION:Insert the terminal until the “click” sound is heard. Verify the protrusion of the water proof seal is
aligned (A) to the other terminals.
Page 16 of 19
ATTACHMENT II
SSP89
7. Confirm correct position of the switch wires and switch, then align the colored outer handle with the hook (B)
at the harness end then move the cover down into position with the rubber button and snap into place.
CAUTION:Prior to reinstalling the cover make sure the switch wires are positioned correctly at the rear
screw hole (A) location.
Page 17 of 19
ATTACHMENT II
SSP89
8. Install the three new screws.
9. Reinstall the plastic screw cover at the harness end making sure the plastic cover in positioned under the
tab (A) as shown below.
10. Install new foam pad at the switch end of the handle.
Page 18 of 19
ATTACHMENT II
SSP89
11. Reinstall the door handle into the door and end cap/key cylinder assembly.
12. Tighten the silver T25 torx screw.
13. Reinstall the lock rod clip to the lock rod.
14. Reinstall the plastic hole cover.
15. Reconnect the Advanced Keyless Entry door handle connector to the door harness.
16. Reinstall window regulator, window and door trim in the reverse order.
17. If you have not already done so, repeat the rubber button inspection procedure for the passenger side outer
door handle.
18. Reinstall the fuse and cover.
19. Verify that the Advanced Keyless Entry system operates properly.
F. CAMPAIGN LABEL INSTALLATION
1. Fill out a blue “Campaign Label” (9999-95-065A-06) with Campaign No: “SSP89”, your dealer code, today’s
date, and affix it to the vehicle’s hood or bulkhead as shown in “B. VEHICLE INSPECTION PROCEDURE”.
CAMPAIGN
LABEL
CAMPAIGN LABEL
CAMPAIGN NO:_____________
DEALER CODE:_____________
DATE:
P/N 9999-95-065A-06
campaign_label
CAMPAIGN
LABEL
1326b
2. Return vehicle to customer.
Page 19 of 19
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TSB/Document ID: SSP-89
Replacement Service Bulletin Number: SSP-89-A
MFR Communication Date: 2012-02-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: LATCHES/LOCKS/LINKAGES:DOORS:LATCH
MFR Component System:
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