NHTSA ID Number: 11006891
Manufacturer Communication Number: 03-001-24b
TSB/Document Date: 2024-09-04
Summary
Some vehicles may experience differential oil leaking from the oil seal (RH side) at the front differential. This is caused by an inappropriate assembly process of the front differential to the oil pan (vehicle side). To eliminate this concern the front differential assembly process has been changed.
BULLETIN NOTES
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted in Red.
Previous TSBs:
Date(s) Issued:
03-001/24
04/03/24 and 02/06/24
03-001/23
12/20/23
SA-075/23
11/13/23
APPLICABLE MODEL(S)/VINS
2024 CX-90 with VINS lower than JM3KK******139377 (produced before September 30, 2023)
DESCRIPTION
Some vehicles may experience differential oil leaking from the oil seal (RH side) at the front differential. This is caused by
an inappropriate assembly process of the front differential to the oil pan (vehicle side). To eliminate this concern the front
differential assembly process has been changed.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify the customer concern.
2. Drain the front differential oil [FRONT DIFFERENTIAL OIL REPLACEMENT (AWD)].
3. Remove the front differential [FRONT DIFFERENTIAL REMOVAL/INSTALLATION (AWD)].
4. Replace the LH side front oil seal (side gear).
a. Remove the front oil seal (side gear) from the front differential carrier
using a flathead screwdriver.
NOTE: To prevent damaging the inside of the front differential casing, wrap a cloth on the end of the screwdriver.
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08/08/2024 01:36 PM tlawrenc
NOTE: SST 49T034201A
b. Install the new front oil seal (side gear) using the SST and a hammer
NOTE:
• Apply front differential oil to the lip of the new front oil seals (side gear).
• Make sure to install the front oil seals (side gear) straight.
5. Replace the RH (oil pan side) front oil seal (side gear).
a. Remove the front oil seal (side gear) from the front differential carrier using a flathead screwdriver.
NOTE: To prevent damaging the inside of the front differential casing, wrap a cloth on the end of the screwdriver.
NOTE: SST 49T034201A
b. Install the new front oil seal (side gear) using the SST and a hammer.
NOTE:
• Install the front oil seals (side gear) straight.
• DO NOT insert the seal until it stops moving. There is a risk of oil leakage due to surface pressure
decrease.
• If the SST is not available, the seal can be installed manually by hand. Make sure the seal is installed
straight in the bore.
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08/08/2024 01:36 PM tlawrenc
6. Clean any oil residue from oil pan to differential matting surface (blue section).
NOTE: If there is dirt or residue of liquid gasket around below hatched area, the differential may leak oil.
7. Apply a small amount of grease to the engine oil pan surface with the front differential.
NOTE:
• Any one of the three options of grease listed below can be used (or an equivalent).
• This procedure is to prevent deformation of the differential oil seal lip during installation.
Brand
Name
Kluber Lubrication
CENTOPLEX 2
Wurth
BRAKE CYLINDER PASTE
Granville
GRANVILLE RED RUBBER GREASE
[How to apply grease to engine oil pan]
(1) Put small amount of grease on your finger.
(2) Apply a thin layer of grease all around.
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08/08/2024 01:36 PM tlawrenc
8. Install the front differential to the oil pan as horizontally as possible.
Cross section of oil pan and differential
(1) Oil pan
(2) Oil seal
(3) Differential
9. Install all the parts in reverse order. Refer to [FRONT DIFFERENTIAL REMOVAL/INSTALLATION (AWD)] and
[FRONT DRIVE SHAFT REMOVAL/INSTALLATION (AWD)].
10. Verify the repair.
PARTS INFORMATION
Parts Number
Description
Qty.
Notes
TAA1-27-397A
1
[R]
TAA1-27-238A
1
[R]
G003-25-421
Clip
1
[R]
D651-33-042A
Nut
2
[R]
9956-41-800
2
[R]
T060-26-169A
Pin, Snap
2
[R]
[R]: Replacement parts
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08/08/2024 01:36 PM tlawrenc
WARRANTY INFORMATION
NOTE:
• This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.
• This repair will be covered under Mazda’s Powertrain Limited Warranty term.
• Additional diagnostic time cannot be claimed for this repair.
Warranty Type
A
Symptom Code
76
Damage Code
9H
Part Number Main Cause
Quantity
TAA1-27-397A
1
XXWJTARX / 7.5 Hrs. (PHEV with FCTA)
XXWJTBRX / 7.4 Hrs. (PHEV without FCTA)
XXWJTARX / 7.4 Hrs (H3T MHEV with FCTA)
XXWJTBRX / 7.2 Hrs. (H3T MHEV without FCTA)
Operation Number / Labor Hours:
FCTA: Front Cross Traffic Alert
Front wheel alignment check and adjust.
A0109LAX / 1.3 Hrs. (Wired type 4-wheel alignment
tester)
A0109LAX / 0.9 Hrs. (Wireless type 4-wheel alignment
tester)
NOTE:
• Claim other parts as related parts.
• When the “wheel alignment check & adjustment” is performed at external repair shop, claim the actual invoice
amount with the sublet code “C1”.
• Warranty policy requires a copy of all sublet invoices be attached to the submitted claim.
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08/08/2024 01:36 PM tlawrenc
- 6X better wear protection on critical engine parts than...
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TSB/Document ID: 03-001-24b
Replacement Service Bulletin Number:
MFR Communication Date: 2024-08-06
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
MFR Component Subsystem: Front Differential
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