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CX60 3.3D Inline 6 Transmission Clunk/Bang/Rock On Start Up - Bad News

14K views 37 replies 8 participants last post by  Southeastern  
#1 · (Edited)
Those with an I6 and no doubt aware of the 80's tractor phenomena upon start up with the loud clunk and bang which (on my car at least) rock the vehicle from side to side. For me its always worse the next day after a longish trip.

Having had my car in at the dealers for two weeks with them exploring a plethora of problems, Mazda UK have come back and said that 'Tractor gate' as I call it is perfectly normal.

Mentioned also by Pistonheads review


"But I do take issue with the bizarre whirring noise on start-up. This lasts for about five seconds and is followed by a clunk so severe that it rocks the car, after which the CX-60 finally settles into a regular, subdued idle. I am still flummoxed by that. What on earth is engaging or disengaging underneath to cause that? It’s like an undercarriage being pulled up but a) this is not a plane, it's a car and b) I hadn’t even put the thing in gear at that point"


Best highlighted in this video by my favourite Japanese mechanic being trying to fix so many issues on the CX60 over the past year


I also asked for the 'Fast idle Cleaning' process to be turned off as in my borough in London I can be fined for idling engines and for multiple violations it can extend to something more serious, let alone my neighbours being seriously annoyed me with. Documentation from Mazda says the engine must not been off during this process.

I also asked about Autohold being made a memory function - I knew the answer to this, but wanted to have it in a PQI just in case Mazda ever take note to this common annoyance for most owners.

Dealers response/Mazda to them

'In regards to the clunking noise when first starting the car, the ‘fast idling’ concern, and the auto hold function- we have been advised that these are all completely normal features on the car and cannot be changed in any way'

Baffled as to how Mazda feel this is acceptable on any car let alone a 'premium' touted £50k SUV.
 
#3 ·
Its remarkable that this could be a 'normal' thing! If you haven't heard it in person @PCM, try your dealers I6 demo car sometime and witness its ridiculousness :)

I'll be going to talk to dealer on Monday, I only got this email on Friday afternoon. Theres a few other issues that havent been addressed either, and Mazda have resorted to the their 'we haven't heard of this problem before' when referring to other common issues that we talk about on the FB group like the Autolock not always working and the tailgate randomly opening. I'm very disappointed in Mazda to say the least.

I'm a bit stuck though tbh, as the used car market has seen a price increase in the last month, (as new cars are still having massive waiting listS) cars that where say £40k are now £43-44k, and the stocks have dwindled further, so finding an alternative of similar class is proving to be difficult, as I currently can't put anything more financially in the pot. Plus I will lose the £1500-2000 Ive spent on this car on enhancements/improvements/fixes out of my own pocket.

Rock and a hard place at the moment. I thought if they could solve this issue, and the Koni's looking like fixing the suspension I could get the car to a place where I can live with it more.

The battery drainage hasn't been confirmed but they believe the battery is at fault, so I have a new one of those, so only time will tell on that front.
 
#17 ·
I am Admin :)

You can open a new thread to continue the dialogue, unfortunately the forum controls are quite minimal at the moment (they will evolve at some point) so I cant merge threads or similar. Best to start a new thread and cut and paste any dialogue from here into that.
 
#18 ·
There are a few Bulletins coming on parasitic draw on battery, plus MDARS update to TCM [trans].

DPF burn off is a very neccessary process and should not be disrupted, all common rail diesel do this, if you are experiencing more than normal burn off cycles then this points to too many short distance driving cycles.
Never buy Any diesel if you are doing 20 min or less journeys daily, this is an engine killer. Without DPF activated you will experience fuel wash in sump or engine oil level rising...engine killer.

Can I suggest you guys with Battery drain try to isolate your key fobs over a greater distance from car, as a short distance the PCM is always communicating with key fob and Not going into sleep mode. Suggest using an EMF pouch or Faraday box device. We as owners demand proximity keys for convenience.
 
#20 ·
DPF regeneration and Fast Idle Cleaning are two different things though. I have no problems with DPF regen, and I use my car for short journeys, all my diesels have done that type of driving over twenty years, the key is to ensure every week or two to take it for a spirited 20-30minute drive on the motorward to clean the DPF out. In a decade I've never had a single DPF issue on German motors, so I hope this method will be enough for the Mazda too. The Fast IDle Cleaning is problematic because in areas of London, and no doubt the UK, idling engines is not allowed, and plus it bothers my neighbours, so its just rather silly as according to their own documents its about their choice and design of injectors that it needs this.

Strangely though, the loan I6 I have had for a month has never once activated its Idle Cleaning process, with the same journeys I make every day, whereas my car was doing it numerous times a week.

My key lives 6 stories up vertically and about 50-100 metres away from the car horizontally. I honestly do not think the battery drain is as simplistic as a key fob based on this.
 
#19 ·
Just to add, about this Trans Clunk.
Yes it is very unfortunate and I would be pissed, however in my 40 plus years owning and working with Mazda in fixed operations management (Service and Parts) and Mazda Australia wholesale and visited Hiroshima and Hofu plants in Japan offically there is one takeaway which always applies.

Mazda Japan does not walkaway from customers.
Report issue with Dealer and get them to Record all your problems on RO in writing.
Never go demanding this or that to your dealer as you will not gain a friend.

I have all the confidence that Mazda will resolve this trans/clunk bang, if your Dealer is jerking you off politely tell them you will approach the Dealer Principal or MME or MUK.

I think in time it may be new transmissions for some as Mazda Japan might want some 'in field' Transmission Assemblies sent back to Japan for teardown analysis.
Yes it is disappointing, I wish you well and as soon as I hear new news I will post.

IF YOU CAN SUPPLY ME PRIVATELY your full VIN so I have on forum as a private record to reference back...makes it so much easier.
 
#21 ·
Just to add, about this Trans Clunk.
Yes it is very unfortunate and I would be pissed, however in my 40 plus years owning and working with Mazda in fixed operations management (Service and Parts) and Mazda Australia wholesale and visited Hiroshima and Hofu plants in Japan offically there is one takeaway which always applies.

Mazda Japan does not walkaway from customers.
Report issue with Dealer and get them to Record all your problems on RO in writing.
Never go demanding this or that to your dealer as you will not gain a friend.

I have all the confidence that Mazda will resolve this trans/clunk bang, if your Dealer is jerking you off politely tell them you will approach the Dealer Principal or MME or MUK.

I think in time it may be new transmissions for some as Mazda Japan might want some 'in field' Transmission Assemblies sent back to Japan for teardown analysis.
Yes it is disappointing, I wish you well and as soon as I hear new news I will post.

IF YOU CAN SUPPLY ME PRIVATELY your full VIN so I have on forum as a private record to reference back...makes it so much easier.
My dealer (business manager and service manager) is very much unapproachable about the transmission clunk now. Mazda UK have 'apparently' told them it is normal and will not be remedied and they feel they cannot provide any additional support for it. I have since written to Mazda UK about it, but now almost a week later, I am still awaiting a response. I'll definitely post what they feedback to me.

It is not unusual for people to be experiencing these types of responses from Mazda UK. Every day we hear a new story on social media groups about similar and the 'its the first time we have heard of it before' routine. If Mazda truly are this great customer centric company, I hope we get to see more examples of it.

According the Japanese mechanics, the clunk is coming from a black box under the car they showed in one of their videos.

I'll drop you my VIN if you think its useful in these matters, in the hope it will get it solved for myself and other I6 owners.
 
#22 ·
YES VIN definitely, look please give me your VIN here as this will give me a reference to Search and then re-check with Mazda EPC (Electronic Parts Catalog) for changes and interchangeability of parts.
You would be surprised what I can extrapolate from an New OWNERS VIN and the Genuine Mazda EPC.

A change in part number for assembly and or small parts will tell me its interchangeability and how the new part can be replaced, like old for new or new for old, or one way only (a new part can be used as a replacement but the old part number (the part) can not be used in car), etc, etc, the dates when replaced or updated on production line, etc.
So I can use your VIN and check now., and then in a few weeks time.

But yes I have seen online that reviewers and most are complaining about clunk etc, these trans have no traditional torque converter but a lock up clutch (basically).

Get back with VIN.
 
#25 ·
I just wish Mazda would say 'yes we know its an issue, we are working on it'

instead of what they did say

'The transmission clunking is normal and we will not be offering any support for this problem to you or your dealer workshop'
 
#28 ·
You have to remember Dealers don't make your car, Mazda Japan does and yes any fix takes time.

I have just put up a new TSB Bulletin details on CX-60 PHEV 1 to 2 Transmission Shift Shock via a Software Update.

 
#29 ·
I remember that very well, however my money was paid to my dealer, so they are my entire source of information and contact, technically speaking. If we remove this forum, and others, then that is the ONLY source of information and if they continue to make things up, then thats a problem, being they are the public face of Mazda.

Im aware you have huge faith in Mazda as you have been with them for a long time and have seen how they operate behind the scenes, but for mmany people the CX60 is their first introduction to Mazda, and many folk have had their cars sit in their dealer workshops for months awaiting repairs. Thats a lot to ask for a premium price point imo. If I had not have fought for a loan CX60, I would have been forced to use their standard Mazda2 courtesy car for this period!

This being a diesel thread means the PHEV transmission update isn't of much interest here! I do wish it was a Diesel update for the jerkyness. But happy PHEV owners are getting a remap to solve their issues.
 
#31 ·
a little update to this...

It took Mazda over a year to finally accept there is a fault somewhere with the Transmission after sending a plethora of videos to them highlighting it and also as the problem was getting worse with low speed jerking and bunny hopping.

They opted to replace the entire gearbox - this was a full engine out job, took 3 weeks for the dealer to do...an entire new gearbox was fitted (but even on my request they refused to fit a new flywheel), everything was good, quiet no bangs, no knocks, and no jerking for 150 miles, and then they started again.

Yey another PQI to Mazda, and if they come back with 'replace the flywheel' which I suspect they will, then the entire engine and box have to come out again.

Mazda and the dealer are doing everything they can to prevent replacement or refund of this vehicle, even though , by law in the UK, they should have refunded it now as the problem was reported within the first six month, has had more than one attempted fix (over 6 'fixes') and it still isn't repaired. but the dealer denies a refund.
 
#33 ·
Thanks, i appreciate that. The amount of parts that have been changed on this car now over the past 18 months is unreal. More than most cars have in their life time.

I asked Mazda to replace the car back in March 24 and they refused. I asked dealer to refund it under consumer law, he refused. They seem to want to do anything they can to avoid it - my theory is, they know how bad of a car it is, and the loss will be heavy as they could'nt really resell it easily.

I am thankful, even though the dealer workshop has had a lack of investment in it from the owner so it looks more like a backstreet garage than a main dealer unit, the technician who works on my car is absolutely A1 and a credit to the firm. I don't think all of this work being done wouldn't have gone as smooth if it weren't for him.

Sadly, my car also came out with a dented rear bumper and cracked lower trim while it was there for three weeks. It happened in the period of dropping off and the technician receiving it, so more £££ of my own money to fix it which wouldn't have happened if it hasnt needed to go in for this work.

In theory, because the gearbox problem happened in the first month of ownership, March 2023, this should have happened then, but how ridiculous on a brand new car!

Image
 
#34 ·
Sorry I don't want to sound difficult, I am not there but I tell you now that Mazda Dealer would not pass muster. Just looking at condition of Workshop, the floor of workshop, hoist (you call a ramp) it all looks late 1980s.
And yeah it is probably an area where customers don't normall see? but all that oil and grime gets dragged into owners cars causing more problems.

Having actually done this and my Service Department would have won the Dealer of Year for my State but I lost because I had no "Mazda" sign hanging on the workshop wall, my Parts Department won (I was fixed operations manager) however the point I am making is Mazda Australia is extremely fussy on how professional their Metro Dealer Networks are, every year they are assessed on a points system.

If Metro Dealers don't ship up you are shipped out and you lose your franchise. The franchise that the Dealer Principal originally signed up for.
All metro Dealers have workshops that are surgically clean. ;)

Agree this Workshop certainly looks like it has had no investment put into it for decades, do they sell many new cars, this looks rural where up to 3 cars are sold each month.

Then to have damage inflicted on your CX-60 while @ Dealership also confirms to me how poor it is.
 
#35 ·
Yeah I have similar ethos to you, my workshop was spotless, and on a whole it was a right pain keeping it that and quite expensive in the long run, but it shows respect to your customers and your team that the conditions are as good as is feasibly possible. They seem fairly successful in the area, but I think their legacy was selling small family hatchbacks to people who aren't that fussed about their car as long as it drives, many owners spending £50k on 'premium' vehicles have different expectations and they were not ready for that, and still seem to refuse it as a thing. This was the dealer that rang around other dealers, illegally using my personal details (we have a GDPR law here) 'blocking' me from getting the car repaired with another dealer, and then took away the option of a courtesy car when I brought it to them, which had to be the way, as they have blocked me elsewhere. They are also aware the car is the sole transport for a disabled person, nice huh?

Yeah those lifts are old, can't see how they are going to cope with the CX80 arrival soon. You can see the workshop as they have two entrances, and the rear one is the step free disabled access which has the workshop open in the summer at least.

I know you're a real ambassador for the brand, and by the sounds of it in Aus, for good reason. Unfortunately Mazda UK definitely don't seem to be of the same calibre. We hear stories similar to mine time and time again from owners who have ended up with bad cars.

To give an example, I am stuck with 'Zoe' a Customer Relations Manager at Mazda UK. She would often make up stories to suit her own rhetoric and state them as fact, often personal things, for example, apparently I agreed to a set of terms and conditions last year where I gave up all of my consumer rights in this car . Obviously laughable, so when asked for evidence of it this, she said its in an email. So I asked for copies of this email, and then came the cagey responses of 'it will take seven days to forward you an email as they have to be checked' (she actually said that), I was like, Zoe, if this is my email, then I already know the content, so just forward it to me. Two months on, still no email. When I asked for Zoe to be taken off my case, I received an email, unsigned but from Zoes computer at Mazda HQ (lol), stating to go to the Ombudsman.

Its very much Zoe and the dealer that brings the brand into disrepute, I am fairly confident if someone looked at my case with impartiality at Mazda, the car would be replaced, but her ego has 'locked' me into to her computer, so to speak.