Random As Rhyme

I am the owner of a 2004 Mazda 3 and while I am mostly happy about my purchase there is one issue with the car that bothers the hell out of me and that is the fact that my 5 year old car is developing what could turn into a serious rust problem. At first I thought it was just my car, but bit by bit I noticed more owners were complaining about this problem.

When I was researched this car I put Mazda 3 rust, Mazda 3 rust problems, etc into google and I didn’t really find much information. With this post I hope to be able to be a resource potential buyers and current owners can use to tackle this issue.

Which years are affected?
04-06 Mazda3 hatch’s and Sedans have been confirmed as being susceptible to premature rusting.

The hatchbacks rust in the following places:

Near the rear doors above the side skirt (stone chips start the process)

The front facing surface of the rear arches near the side skirt.

The rear bumper seems at the fender arch’s

The sedans rust in the following places:

The rear bumper seams

Around the third brake light

The forward facing rear fender arches near the side skirt (same spot as the hatches)

Rocker panels

For more info on what spots to check and pictures of other vehicles:
http://www.mazda3forums.com/index.php?topic=107859.0
http://www.torontomazda3.ca/forum/showthread.php?t=25439

I rustproofed my car do I still have to worry?
Yes.

I rust proofed my car with Krown upon taking ownership and it only slowed the rust down, how much I can’t say. I do not believe the previous owner rust proofed the vehicle however other owners have reported rust proofing their vehicle and the rust continuing anyway.

Whats the cause?
This is still up in the air but here are a few things I have read:

“The problems your having are as result of Mazda Developing the World’s First Environmentally Friendly Coating Technology back in 02.

The Protege5’s were the first to get it, thus resulting in thinner paint and rusting issues. Obviously Mazda 3’s are suffering as well.

Mazda has successfully developed a new environmentally friendly coating technology. It reduces the emission of volatile organic compounds (VOC) to the same level of VOC regulation in Europe where waterborne paints are mainly used, while achieving reduction of CO2 discharge and better coating quality. This significant technology has been launched at its Hofu Plant 1 in Yamaguchi Prefecture. The new technology is called “Three Layer Wet Paint System.” Primer coating process is combined into the top coating process aiming to reduce environmental impact comprehensively.
”
“I sent pictures to the dealership, to Mazda Canada, to Mazda HQ in Japan with no results. They will not respond.
The best body shop in our area figures its likely recycled steel and poor paint/rust inhibitor application. They don’t want to touch it as they can’t guarantee the job.
His advice was ‘pretty it up and unload it’.”

“According to the TSB, “Some vehicles may exhibit a bubbling or blistering under the paint on aluminum body parts. This is due to iron contamination of the aluminum panel. . . . Ford’s Scientific Research Laboratory has performed a number of tests on vehicle body parts returned for corrosion related concerns. Testing has revealed that the aluminum corrosion was caused by iron particles working their way into the aluminum body part, prior to it being painted.”

CAS Executive Director Clarence Ditlow said:
“This is a very expensive defect to remedy. The TSB requires “extreme care to be taken” including special tools and segregated work areas to remove the corrosion by blasting, re-priming and repainting. This repair is so difficult that CAS recommends the best fix is to replace the corroded part with a primed steel part and paint it. Ford cannot guarantee this repair will eliminate all the iron corrosion or prevent other areas from bubbling or blistering in the future.””

I have rust what can I do?
First of all, if you live in Canada tell them that you are on a list submitted by Lynne M. Witty and have been contacted by Mazda about having your rust repaired under warranty.

Do NOT let them turn you away and say that there is no such warranty or you are ineligible for service. This is flat out wrong my 04 with 138 xxx km was approved by Mazda Canada and cars with higher mileage than mine have also been approved. Early on Mazda was turning people away now however they know it is a problem and do not want it getting out of hand however there is an open ticket with the Automobile Protection Agency regarding this issue.

Be kind and courteous but also firm, you have a problem you know it’s not just your problem and they need to fix it.

Here are some links to success stories in getting the rust fixed via the dealer:
http://www.canadiandriver.com/forum/index.php/topic,61821.0.html
http://www.torontomazda3.ca/forum/showthread.php?t=26095&page=2
http://www.torontomazda3.ca/forum/showthread.php?t=31905
http://www.torontomazda3.ca/forum/showpost.php?p=392234&postcount=87

How did you handle your car?

I went in to Erin Mills Mazda 3 weeks ago to see if I could have my rear fender arch rust repaired under warranty from Mazda Canada.

I never purchased a warranty through Mazda and had no paper work to show, and my car is a 2004 with 134 xxx km.

I went in and spoke with service adviser Ignatius Xavier and he made an appointment for me to meet with the body shop representative take pictures and have my claim submitted to Mazda of Canada.

My estimate was about 1300 worth of work and was approved withing 3 days of submission by John Riexinger the district parts and service Manager.

I dropped my car off last Thursday and drove it home complete today. The work was done by Oakville Honda and looks great.

The hardest thing I had to deal with was driving my girlfriends Civic. This was the most painless warranty claim I have ever done.

I recommend anyone who is having issues getting their rust repair authorized try this dealership.

Should I still consider a Mazda 3?

That is up to you. Rust aside I am very happy with my car, it’s been the most reliable car I have owned, however I do not think I could own it as long as I owned my first car (7 years) and expect the body to hold up as well as it did, which is a shame. This problem may have been remedied in later models or it might just not be present yet. In the end the choice is yours.