Recall - Outer Front Door Handle
1988-1991 626 & 1988-1989 929Outer Front Door Handle
[Recall Campaign No. 53404]
To: All Mazda Dealers
Attention: All General Managers, Service Managers & Parts Managers
Subject:
Recall Campaign No. 53404
1988-1991 626 & 1988-1989 929
Dear Mazda Dealer:
Mazda Motor Corporation has decided to conduct a Recall Campaign to install safety shields on certain 1988-91 626 & 1988-89 929 models beginning April 29, 1994.
We have determined that a defect, which relates to motor vehicle safety, exists in certain 1988-91 626 models with molded plastic (chrome plated) outer front door handles and 1988-89 929 models with molded plastic (chrome plated) outer front door handles.
We are requesting that you install a safety shield between the window and the door latch mechanism in the front doors of all affected vehicles. Should the door handle break, this will prevent the door latch actuating rod from failing into the path of the window, where it could possibly release the door latch and cause the door to open. In addition, the outer front door handles are now covered by a lifetime warranty against defects in materials or workmanship.
Detailed information regarding this Recall Campaign is provided in Attachment I, the Recall Campaign repair procedure is shown in Attachment II, and the letter sent to the owners of the subject vehicles is shown in Attachment III.
Please make certain that the appropriate personnel in your dealership are familiar with the details of this Recall Campaign for responding to customer inquiries. Should you have any questions, please contact your District Customer Support Manager.
We apologize for the inconvenience this may cause you and your personnel. Your understanding and support in carrying out this campaign is greatly appreciated.
Attachment I
1. SUBJECT VEHICLES
2. OWNER NOTIFICATION
The owners of the subject vehicles will be notified by first class mail beginning April 29, 1994. The following is the mailing schedule:
Model Year & Model Mailing Dates
1988 929 April 29
1989 929 May 6
1988 626 May 13
1989 626 May 20
1990 626 May 27
1991 626 June 3
3. REPAIR PROCEDURE
Please refer to Attachment II.
4. CUSTOMER REIMBURSEMENTS FOR PREVIOUS REPAIRS TO OUTER FRONT DOOR HANDLES
The customer reimbursement procedure is a function of Mazda Motor of America, Inc. and not the dealer. Reimbursement application forms are being sent to all owners. (Attachment III)
5. WARRANTY INFORMATION
NOTE:
1. Only broken door handles due to a defect in materials or workmanship are covered by this warranty. Campaigning/Add-on replacement of both door handles will be subject to debit.
2. Two new process numbers have been provided in addition to the two originally printed in the first recall letter.
6. PARTS INFORMATION
During trial installations of the safety shields, we found that the 626 beltline molding clips would occasionally break during the repair and require replacement with new clips. No clip breakage occurred on the 929 models.
Additional beltline molding clips, supplied in the 626 safety shield kit, must only be used to replace broken clips. Return any unused, extra clips from the repair to your inventory. Extra clips from one safety shield installation may be required on another.
Always reuse the beltline molding clips, unless broken during R&R.
1 - 626 Safety Shield Kit P/N G2Y1-59-41X consists of the following parts:
1 - Pair of safety shields that can be used on either side
3 - White beltline molding clips
1 - Yellow beltline molding clip
1 - 929 Safety Shield Kit P/N H2Y0-59-41Y consists of the following parts:
1 - Pair of safety shields (one right side only & one left side only)
An initial quantity of recall labels is enclosed for your use. Recall labels are supplied at no charge. If additional labels are needed, please order through:
HELM, Inc.
(800) 782-4356
Quantity of 1 = 13 Labels per 8-1/2" x 11" sheet
Part Number: 9999-95-065A-00
Safety shield kits are being drop shipped, based on the percentages of the forecasted 70% Recall Campaign completion rate, for the vehicles currently registered in dealers' assigned market areas:
929 AND 626 DOOR HANDLE RECALL CAMPAIGN No. 53404 - Attachment II
REPAIR INSTRUCTIONS
To Avoid Damage To The Vehicle, Read All Instructions And Warnings First
INSPECTION AND VERIFICATION
1. Verify the vehicle's VIN and that the door handles are chrome plated not body colored.
2. Check driver's side door for recall campaign label # 53404.
^ If the label is present, the recall campaign has been performed.
^ If no label is found, proceed to the next section for 929 models or previous section for 626 model vehicles.
INSTALLATION OF SAFETY SHIELD
Install the plastic safety shield on both front doors according to the following instructions.
1988 - 1989 929 Models:
VIN JM1HC221***10001 - 222216
1. Open door and lower door glass fully.
NOTE:
Do not remove side view mirror on 929 vehicles.
2. Carefully remove outside beltline molding. Begin removal at the rear clip. Refer to figure 2.
3. Move the molding toward the rear of the vehicle to avoid interference with the triangular (sail shaped) garnish around the side view mirror.
4. Install the left safety shield on the left side belt line molding and the right safety shield on the right side beltline molding.
NOTE:
Shields are marked with a "L" and "R" for identification. Apply silicone spray to the mounting area to ease installation. If installing the shield during cold weather, soak the shield in warm water for 5 minutes prior to installation.
^ Butt the rear edge of the safety shield up against the front edge of the beltline molding yellow clip (rearmost clip). Refer to Figure 3.
* Gently push the safety shield on to the beltline molding.
WARNING:
Do Not Force The Shield onto The Molding. Press the shield into place slowly and carefully. Apply thumb pressure directly over the attachment tabs.
If attachment tab on the shield is broken, replace the shield with an undamaged part.
5. Remove all excess silicone spray.
6. Install the beltline molding onto the door. It is not necessary to install new clips.
7. After installation, check the window operation. Windows should operate smoothly with no noise (rubbing or scraping).
8. Install the campaign label on the driver's side door. Refer to Figure 1.
9. Wash vehicle windows prior to returning to customer.
1988 - 1991 626 Models:
VIN JM1GD22***500001 - 917464 (4dr)
JM1GD24****S0001 - 835795 (5dr)
1YVGD22B***100001 - 274256
1. Open door and lower door glass fully.
2. Remove inner triangular (sail shaped) garnish from the side view mirror.
^ Pull the top edge free first to free the push in spring clip. Refer to Figure 5 (top).
WARNING:
The lower portion of the garnish is secured by two (2) "L" shaped clips. These clips will break if the garnish is pulled directly out.
^ After pulling the upper clip straight out, let the garnish hinge inward from the window.
^ Lift the bottom portion of the garnish straight up to remove. Refer To Figure 5 (bottom).
3. Remove door mirror.
^ Remove the three (3) screws securing the mirror.
^ Do not remove the white triangle plastic retainer.
^ Unplug power mirror connector (if equipped).
NOTE:
Do not let the mirror hang. This will damage the door paint.
4. Carefully remove the outside beltline molding.
^ Begin by removing the black phillips head screw located on the inner side of the door, at the rear of the molding. Refer to Figure 6.
^ First gently pull the molding up to free four clips.
^ Second, move the molding back toward the rear of the vehicle to free the molding from the nonremovable front clip.
WARNING:
If you attempt to pry the front clip off by upward pressure, the molding will break. Do not twist the molding to remove, twisting will break the clips and damage the molding.
5. Install the safety shield on the beltline molding. Refer to illustration. READ NOTE BELOW PRIOR TO INSTALLATION.
NOTE:
Apply silicone spray to the mounting area to ease installation. If installing the shield during cold weather, soak the shield in warm water for 5 minutes prior to installation.
^ Butt the rear edge of the safety shield A up against the front edge of the beltline molding yellow clip (rearmost clip). Refer to Figure 7.
^ Gently push the safety shield on to the beltline molding.
WARNING:
Do Not Force The Shield Onto The Molding. Press the shield into place slowly and carefully. Apply thumb pressure directly over the attachment tabs. Refer to figure 8. If attachment tab on the shield is broken, replace the shield with an undamaged part.
6. Install the beltline molding onto the door in reverse order of removal.
NOTE:
In the event the clips are damaged during removal, spare clips are enclosed with the safety shields. Do not install the molding without the correct number of clips. It is not necessary to install all new clips. Replace only those which were broken during removal.
7. Install the side view mirror
8. Install triangular shaped garnish:
^ First insert the two (2) "L" shaped tabs.
^ Second, swing the top of the garnish inwards securing the spring tab into the proper receptacle.
^ Remove all excess silicone spray.
9. After installation check the window operation. Window should operate smoothly with no noise (rubbing or scraping).
10. Install the campaign label on the driver's side door. Refer to Figure 1.
11. Wash vehicle windows prior to returning to customer.