01-002-13-2753

Service Bulletin
Mazda North American Operations
Irvine, CA 92618-2922
© 2013 Mazda Motor of America, Inc.
Subject:
2009-2012 MAZDA6 - RATTLE NOISE AND/OR EXHAUST LEAK NOISE FROM
REAR OF VEHICLE
Bulletin No:
01-002/13
Last Issued:
01/14/2013
2009-2012 MAZDA6 - RATTLE NOISE AND/OR EXHAUST LEAK NOISE FROM REAR OF VEHICLE
BULLETIN NOTE
• This bulletin supersedes the previous bulletin 01-025/12, issued on 11/16/12. The DESCRIPTION has been
revised.
• Changes are noted below in Red beside the change bar.
APPLICABLE MODELS/VINS
2009-2012 Mazda6 vehicles produced before June 7, 2012
DESCRIPTION
Some vehicles may exhibit a rattle noise and/or exhaust leaking noise from the rear of the vehicle. The noise
may be caused by a gap between the exhaust hanger bracket and flange, which allows moisture containing
road salt to enter and cause the exhaust studs to rust and possibly break off.
The welding location of the exhaust hanger bracket and flange has been changed during vehicle production to
ensure the hanger bracket and flange are flush, with no gaps that could allow intrusion of moisture containing
road salt.
The purpose of this bulletin is to cut and clean the welding location of the exhaust hanger bracket and re-attach
it, so the hanger bracket and flange are flush with no gaps, to prevent intrusion of moisture containing road salt.
Customers having this concern should have their vehicle repaired using the following repair procedure.
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CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
Bulletin No: 01-002/13
Last Issued: 01/14/2013
© 2013 Mazda Motor of America, Inc.
REPAIR PROCEDURE
Replace any broken or missing exhaust studs between the main silencer and pre-silencer.
1. Verify customer concern.
2. Safely raise vehicle on hoist.
3. Locate the exhaust joint between the main silencer and pre-silencer as shown below.
2.5L Engine:
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Bulletin No: 01-002/13
Last Issued: 01/14/2013
© 2013 Mazda Motor of America, Inc.
3.7L Engine:
4. Inspect for broken or missing exhaust studs:
- If either stud is broken or missing, proceed to the next step.
- If neither stud is broken or missing, refer to the instructions on MS3 online or the Workshop Manual for
further troubleshooting information.
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Bulletin No: 01-002/13
Last Issued: 01/14/2013
© 2013 Mazda Motor of America, Inc.
5. Remove the main silencer:
a. Spray rubber hanger that supports main silencer to ease the removal from the body hanger.
b. Remove stud nuts and discard them.
c. 3.7L Only: Remove nuts from the crossover pipe, then discard the nuts and gaskets.
d. While supporting the main silencer, remove the rubber hanger from the body hanger, then place the main
silencer on a work bench.
e. Remove gaskets and discard them.
6. Press out both broken and unbroken studs from main silencer flange that mates with the pre-silencer flange:
a. 3.7L engine right main silencer shown below (2.5L engine is similar).
NOTE: Take care not to bend or damage the flange while pressing out the studs. Make sure both sides
of the flange are supported as shown above.
b. Using a wire brush, remove any loose rust on the flange the studs were removed from.
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Bulletin No: 01-002/13
Last Issued: 01/14/2013
© 2013 Mazda Motor of America, Inc.
7. Locate the hanger bracket that supports the rear of the pre-silencer.
a. Remove the rubber hanger from the rear hanger and support the pre-silencer with the tall jack stand.
b. With an angle grinder, remove the welds (A) that attach the hanger bracket to the flange (in order to separate the bracket from the flange).
c. Remove any weld or weld splatter from the nut tightening surface of the hanger bracket (B). Also, remove
the remaining weld from the flange that was attached to the bracket and make it a smooth surface.
d. Remove any loose rust from flange surface behind the hanger bracket and the hanger bracket itself.
8. Prep rubber hangers and install separated pre-silencer hanger bracket:
a. Spray liquid lubricant on rubber hanger for the main silencer where it connects to the body and the rubber
hanger that is used for the rear pre-silencer hanger bracket.
b. Install the separated hanger bracket to the rear pre-silencer rubber hanger.
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Bulletin No: 01-002/13
Last Issued: 01/14/2013
© 2013 Mazda Motor of America, Inc.
9. Reinstall the main silencer:
a. Lift the main silencer up and attach the rubber hanger to the body hanger.
b. 3.7L Only: Attach the crossover pipe to the left main silencer after installing the new gasket and hand
start the new nuts.
c. Align the main silencer flange, pre-silencer flanges, separated pre-silencer bracket (front of pre-silencer
flange) and new gasket.
d. Insert new bolts from the main silencer side and hand start the nuts to the bolts from the pre-silencer separated hanger bracket side as shown below.
e. Align the flange edges so there is no overlap on any side.
f. Torque the joint by putting the torque wrench on the bolt head and hand wrench on the nut.
Tightening Torque: 36.9 ft. lbs. {50 N-m, 5.1 kgf-m)
g. 3.7L Only: Torque the joint between the crossover pipe to the left main silencer.
Tightening Torque: 33.2 ft. lbs. {45 N-m, 4.6 kgf-m)
10. Verify repair:
a. 3.7L Only: Check that all the joints have been secured.
b. Check that the rubber exhaust hangers are in correct position.
c. Start the engine and confirm the noise has been eliminated.
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Bulletin No: 01-002/13
Last Issued: 01/14/2013
© 2013 Mazda Motor of America, Inc.
PART(S) INFORMATION
Part Number
Description
Qty.
Notes
9978-11-035
Bolt
2
---
9994-61-000
Nut
2
---
L505-40-305B
Gasket
1
---
CA01-40-306A
Gasket
1
Additional parts for 3.7L engine
9XG0-54-43ZA
Nut
2
Additional parts for 3.7L engine
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 New Vehicle Limited Warranty term.
Additional diagnostic time cannot be claimed for this repair.
Warranty Type
A
Symptom Code
82
Damage Code
9Y
Part Number Main Cause
Quantity
Operation Number / Labor Hours
L505-40-300D
0
YY742XRX / 0.5 Hrs. (2.5L Engine)
YY746XRX / 0.6 Hrs. (3.7L Engine)
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