Summary
The Mazda6 has 43 recalls spanning the 2002-2019 production run, with the most serious being Takata airbag inflators on 2003-2008 models that can rupture during deployment and send metal fragments into the cabin, causing serious injury or death.
The Takata inflator issue extends beyond its initial recall: 2003-2008 vehicles that had their passenger-side inflators replaced under an earlier campaign received units of the same flawed design, meaning the prior repair did not fully resolve the hazard. Separately, the 2004 model year has both driver and passenger airbag inflators that can over-pressurize and rupture, rear seatbelt retractors that may not lock in a crash, and a fuel sender unit that can leak due to an improper seal.
On the most recent production years, 2018-2019 vehicles have a software error in the powertrain control module that can cause an unexpected engine stall while driving. The 2018 model alone also has a fuel pump that can fail without warning, cutting engine power while in motion. The 2017 model has a narrow trim-specific issue where certain vehicles equipped with optional fog lights have an incorrect combination switch that prevents turn signals from self-canceling after a turn.
The 2016 model has weld spatter on the front passenger seat frame that can chafe the wiring to the passenger seat's occupant classification sensor, potentially killing power steering assist and disabling the entire airbag system at the same time. The 2014-2015 model years share a parking brake concern where water enters the caliper, corrodes the actuator shaft, and leaves the brake either unable to hold the vehicle or dragging while driving. Those same years also have a tire pressure monitoring system that can fail to alert the driver when all four tires lose pressure simultaneously, and a fuel tank that can be overfilled, sending fuel into the charcoal canister and creating a fire risk.
The 2010-2012 models with the 2.5L engine face a distinctive problem where certain spiders can weave webs inside the evaporative canister vent line, blocking it and creating negative pressure that can eventually crack the fuel tank and cause a fuel leak. The same spider-web issue affects 2009 models. The 2009-2010 models registered in salt-heavy regions also have a lower control arm mounting point that can corrode and unexpectedly shift steering alignment, and an airbag control unit that may fail due to moisture, preventing airbag deployment in a crash. The 2009 model has door latches where the handle can stick and prevent the door from closing fully, allowing it to swing open while driving, and door latch mounting screws that can loosen over the same era through 2013 models.
The 2011-2013 models sold in salt-belt states have a subframe corrosion issue at the passenger-side lower control arm mount that can alter steering alignment unexpectedly. The 2010 model year has a passenger airbag inflator that can degrade from heat and humidity cycling and deploy with excessive force. Going back further, the 2007 model with California emission specifications has a fuel tank coating that can be damaged during assembly, leaving the steel tank vulnerable to corrosion and eventual perforation. The 2002 model has a brake fluid level sensor float that can be knocked off its guide rail during manufacturing, leaving the low-fluid warning light non-functional.
