33 of the
184 complaints filed about the Mazda CX-90 Plug-In Hybrid
are about the engine —
18% of everything owners reported.
The worst model year for it is 2024.
Dear NHTSA Team, I am writing to formally report and follow up on a safety-related issue regarding my 2024 Mazda CX-90 PHEV, VIN: [XXX] . The vehicle has experienced repeated defects affecting critical safety systems, including: Engine overheating and cooling system failures Repeated engine malfunction warnings EVAP/emissions-related system faults These issues have persisted despite multiple visits to authorized Mazda service centers, and no permanent repair has been achieved. The defects raise serious concerns regarding the vehicle’s safety, reliability, and potential risk to road users. I have submitted a complaint via NHTSA’s Vehicle Complaint system but would like to confirm receipt and request the current status of my case, or any guidance on next steps. Please let me know if additional documentation, service records, or details are required. I am fully willing to cooperate to ensure this matter is properly reviewed. Thank you for your attention and assistance. Sincerely, Dr. [XXX] [XXX] Phone: [XXX] Email: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11705472 — an unverified report by a vehicle owner.
I am reporting serious safety concerns with my Mazda CX-90 PHEV (leased, manufactured September 2023). These issues create unacceptable risk to occupants and other road users. Multiple Severe Recalls: My vehicle has had at least four major recalls: • 6323J – Engine & Motor Shutdown: Complete loss of propulsion without warning. • 7024J – ECU Software Failures: Loss of drive power and restart failures. • 24V817000 – EV Mode Power Loss: Sudden propulsion loss in EV mode. • 6724E – Sudden Braking: Automatic braking without cause. These defects could lead to crashes or fatalities. Hybrid System Malfunctions: Two recent “Hybrid System Malfunction” warnings required dealer visits. These failures could cause the car to shut off while driving—even at highway speeds. • First incident: Battery-related issue. • Second incident: Triggered by a loud noise during startup, impacting the AVAS system. A loud noise should never disable a family vehicle, indicating a design flaw. Charging Safety Issues: Charging via a standard outlet caused flickering lights and breaker buzzing in my house. A licensed electrician diagnosed harmonic distortion from the onboard charger. I spent $7,500 on electrical upgrades (dedicated EV line and panel upgrade) to charge safely. Manufacturer Response: I have had an open case with Mazda corporate for nearly two weeks. They refuse to acknowledge overall vehicle safety or provide written documentation confirming safety. Request: I urge NHTSA to investigate whether these defects represent a systemic safety issue in Mazda CX-90 PHEV models and take appropriate regulatory action
NHTSA complaint #11704628 — an unverified report by a vehicle owner.
After driving >2000 miles or about a month, I could hear a loud, grunting/grinding noise when accelerating aggressively from 1st to 2nd gear when on EV or gas mode. Brought the vehicle at the dealership service department 4 times already, each time MAZDA Headquarters in California confirmed that this is a known and documented condition. According to Mazda, the grunt noise you’re hearing when the vehicle shifts from first to second gear under medium to aggressive throttle is considered normal operation. It has been determined that this does not affect the drivability or reliability of the vehicle, and it is safe to drive. The transmission is operating as designed and performing within normal parameters. Mazda is continuing to collect data on this condition as part of their ongoing commitment to improvement. However, I totally disagreed to their answer and that the truth is that they don't know how to fix it, unless tearing down completely the transmission to find out what the cause is! I feel it is a safety problem as explained by a top transmission repair shop: "In most cases, a loud, grunting or grinding noise when accelerating from 1st to 2nd gear would likely be considered a defect that substantially impairs the vehicle's use and could also affect safety, particularly under the context of Oregon's Lemon Law. Here's why: •Impact on Use: Grinding and grunting noises suggest that the transmission is not functioning properly, according to Top Notch Transmissions. This makes the vehicle less reliable and less enjoyable to drive. If the problem persists or worsens, it can hinder the vehicle's ability to operate safely and effectively, potentially leading to hard or delayed shifting, or even transmission failure."
NHTSA complaint #11690803 — an unverified report by a vehicle owner.
While driving 35 mph on a busy street, our vehicle completely lost power. The vehicle started violently shaking until I came to a complete stop. Many warning lights came on. Two primary: "Hybrid Malfunction", "Engine Malfunction" along with a couple others. When I stopped the car completely, it took 5 minutes before I could change the car from park to drive to move the car out of the way of oncoming traffic. Sitting in the middle of a busy road with hazards on is not safe!! Also, Suddenly losing power on a very busy street caused car behind me to slam brakes and honk at us. Very lucky we didnt cause an accident. If this had happened in a different situation such as freeway at 75 mph, major intersection, on a long roadtrip etc... the risk for significant disaster increase significantly! The car is current at Tum Dahle Dealership in Murray, Utah. This is the second time in 4 months we've had to take this car to the dealer for an issue. The first time was just an "Engine Malfunction" light. It sure seems like we bought a lemon. Even if they fix this car, my confidence is extremely low in this car being a safe car that im ok with having my family in.
NHTSA complaint #11688799 — an unverified report by a vehicle owner.
Ever since the lease of this vehicle on January 2025 we’ve had problems with the brake/rotors took it in twice for that. As of recent August 2025, we took it in for loss of power going up a hill, hybrid malfunctioning electrical system going out. Dealership gave it back saying everything was fine. We took it on August 29, 2025 to Colorado vehicle failed to perform loss of power going up the mountain almost got hit by a vehicle because I was in a fast lane with my family had to pull over with whatever power I had left in the engine (not the battery). I mean the vehicle just keeps failing to perform as it should as well on the way back. It had the same issues but as severe going to Colorado.Vehicle does not change gears going uphill. When we stopped in Vegas for fuel, fuel door did not open it & malfunctioned. So vehicle does not perform well in cold and hot weather AWD system does not work at all. We feel a jerking, we hear a whistling’s type of noise that the dealership fell to inspect. Per them everything worked fine but when we took it to Colorado this weekend for Labor Day, vehicle underperformed with extreme safety concerns and we contacted Mazda, but they fell to listen to our concerns and say the vehicle is fine but when you drive the vehicle, it does not perform as it should and is a safety hazard to us and anybody around us due to a loss of power and everything I described above.
NHTSA complaint #11684407 — an unverified report by a vehicle owner.
On two separate occasions, my young children were locked inside the vehicle, and on one of the two occasions my elderly mother was also locked inside. In all incidents, the doors and windows remained closed and would not unlock, even when attempting to use the key fob. Specifically, after parking, I exited the driver’s seat and closed my door. When I went to open the rear doors to get my children out of their car seats, the rear doors were locked and could not be unlocked by the key fob. The same occurred when my elderly mother was in the vehicle. Each time, the car was in hot conditions, and we were fortunately able — after some struggle — to unlock the doors and remove them from the vehicle. This presents a serious safety risk, particularly in warm weather and with young or elderly passengers who cannot exit the vehicle themselves. I am currently pursuing a lemon law claim for this vehicle, but I also wanted to formally report this defect because of the danger it poses.
NHTSA complaint #11673421 — an unverified report by a vehicle owner.
Issue Summary: Since December 27, 2024, my vehicle has experienced a hybrid malfunction and leakage issue three times. Each time this occurs, the vehicle becomes completely inoperable and cannot move, requiring a tow truck to take it to the dealership. Since December 27, 2024, my car has been in the shop four times, yet the issue persists. This raises serious reliability and safety concerns, as the vehicle can suddenly become unusa
NHTSA complaint #11644694 — an unverified report by a vehicle owner.
The contact owns a 2025 Mazda CX-90 PHEV. The contact stated that the hybrid battery failed to charge above 80 percent, and the "Engine Malfunction" warning light remained illuminated. The vehicle was taken to the local dealer who was unable to determine the cause of the failure. The vehicle was not yet repaired. The manufacturer was notified of the failure. The failure mileage was 25.
NHTSA complaint #11644453 — an unverified report by a vehicle owner.
Vehicle had the dreaded 3 code battery malfunction. Charging system malfunction, critical vehicle malfunction (electrical leakage), & hybrid system malfunction. Making the car unable to drive and have to get towed. The car had me pull over at which point it could not be turned back on. It could not even be put into neutral and had to be pulled onto a flatbed truck. I bought the car on Dec 27th and Dec 28th it was broke down with 126 miles on it. It’s now Feb 22nd and they don’t know how to fix the car. This seems to be happening to many of these cars.
NHTSA complaint #11644319 — an unverified report by a vehicle owner.
While vehicle was in motion, warning light came on stating “engine malfunction, have the vehicle inspected”. Engine light stays illuminated. The message and light now appear at startup
NHTSA complaint #11641492 — an unverified report by a vehicle owner.
At approximately 16:50 engine malfunction warning light appeared and dealership was notified. Appointment scheduled for 4 days after. At 17:21 car began swerving uncontrollably along I80 with warning “engine malfunction, have the vehicle inspected.” The car was shaking violently and veered off the road into the ditch between the eastbound and westbound highway. The car was totaled. Review of the vehicle app indicated that just before the crash at 17:19 several critical vehicle malfunctions messages appeared. The vehicle crashed at 17:21.
NHTSA complaint #11641436 — an unverified report by a vehicle owner.
This is a 2024 Mazda CX-90 PEHV where I took it in for all recalls on January 17th, 2025 related to loss of power and hybrid system malfunction. Today, Jan 31st, 2024 (2 weeks and a few 100 miles later), I now have engine malfunction warnings lights. This car has serious issues that nearly caused a bad accident where POST recall, the issues continue
NHTSA complaint #11639858 — an unverified report by a vehicle owner.
1. Gear Shift Issue in EV Mode: The transition from 1st to 2nd gear is not shifting properly in EV mode. At times, the gear jerks during critical situations, which compromises control. 2. Power Output on Highway: While driving on the highway, there are instances where there is no power output when flooring the accelerator to overtake. 3. Engine Malfunction Light: The engine malfunction light has come on and off three times. 4. Radar Malfunction: The radar system is intermittently not working or working improperly. The radar malfunction light also came on and off once (i-ACTIVSENSE system malfunction). The last safety recall was completed a few weeks ago, but the issues are still ongoing. Since then, I have visited the Mazda dealership twice, but they let me go, dismissing my claims and saying they couldn’t duplicate the problems. I have a case with Mazda corporation. Nothing done yet (Case Number: [XXX]). The name of the Representative is Candy. I would appreciate it if you could investigate these issues at the earliest convenience. Thank you for your attention to these matters. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11632007 — an unverified report by a vehicle owner.
I was driving my 2024 CX90 PHEV when a warning about an electrical leakage in the hybrid system was detected. I brought it home and parked in my garage. I called the dealership and they told me to bring it in. When I started to leave, the car would not shift out of park and bricked up. A towing service had to drag it out of my garage. My concern is that there is no limp mode or any way to switch to the gasoline engine when this happened. Had there been a fire in the battery, I would not have been able to get it out of my garage, putting our house and children at risk. Also, had it locked up on a highway, an accident could easily happen. After the dealership dragged it off of the rollback, they couldn’t even get the car to move. They told me that they would have to order special tools to be able to get the car to move. Along with the steering recall that worked for about a month, the steering rack had to be replaced, and the failure of the electrical system, I feel like this car is unsafe to drive. Thank you.
NHTSA complaint #11623076 — an unverified report by a vehicle owner.
On my way to drop kid to school all of a sudden the car gave up power and shuddered with engine malfunction and I-drive malfunction warning. Check engine light came on. This is risky because another vehicle could have smashed into us if on highway or high speed. Research shows that a whole lot of people have this identical issue.
NHTSA complaint #11620262 — an unverified report by a vehicle owner.
Mazda CX 90 PHEV. When charging on 110 standard outlet or 240v dedicated breaker - Chargepoint charger, the car onboard charger/inverter backfeeds a loud buzzing / humming back through the electrical wire to the electrical panel. It also causes a buzzing/humming in other appliances and causes led lights in the house to flicker. This is with a 100amp breaker panel and a new upgraded 200amp breaker panel. May cause electrical issues up to electrical fire in other areas of the home. Scheduled diagnostic test in vehicle 10/1/24, but other owners report same issue on Mazda CX 90 online forums.
NHTSA complaint #11615291 — an unverified report by a vehicle owner.
July 11, 2024 – Odometer – 7,604, Gas – Full, Electric – 19 Miles range - From work to Home, Receive the following errors “Engine Malfunction, Have Vehicle Inspected” and “Hybrid System Malfunction, Have Vehicle Inspected” warning lights come on. Cars behavior – Air conditioning motor running but not cooling air, Loss of power and car very sluggish (have to be careful at intersections), seems to maintain speed even when taking foot of gas and requires extra breaking, seems to be clunky when transmission upshifts/downshifts at times. When leaving work, did not seem to like being in EV mode even though fully charged (Chargers at work) and would switch itself out of that move and say unavailable. Outside air temperature 90 degree (Air Conditioning not working, very uncomfortable). This defect is dangerous and I serious concerns driving this car such as unpredictable loss of power when entering traffic and hesitation / unpredictability when hitting the accelerator. In addition, with the car maintain speed while not touching the gas pedal and requiring extra breaking is a scary. June 13 – Issue cleared and wanting lights were gone before I was able to take it in for service. July 25th – Recurrence of the same issue - Odometer – 8,162, Gas – Full, Electric – 14 Miles range - From work to Home, Receive the following errors “Engine Malfunction, Have Vehicle Inspected” and “Hybrid System Malfunction, Have Vehicle Inspected” warning lights come on. Cars behavior – Air conditioning motor running but not cooling air, Loss of power and car very sluggish (have to be careful at intersections), seems to maintain speed even when taking foot of gas and requires extra breaking, seems to be clunky when transmission upshifts/downshifts at times. When leaving work, did not seem to like being in EV mode even though fully charged (Chargers at work) and would switch itself out of that move and say unavailable. Outside air temperature 87 degree (Air Conditioning not workin
NHTSA complaint #11604822 — an unverified report by a vehicle owner.
On July 15, 2024 this vehicle at 50 mph on cruise control suddenly flashed white warning words indicating problems with the cruise control and immediately thereafter started flashing “hybrid malfunction” and to return to service dealer. At the time of the hybrid malfunction warning which was right after the quick cruise control warning, the engine operation, specifically the gas pedal no longer delivered power to vehicle, either electric or gas. Additional warning was to pull off to the side and stop and turn off vehicle. This occurred and vehicle was pulled to the side put into park and turned off. Waited approximately 3 to 5 minutes and restarted the engine which started in gas with no electric although there was electrical charge on the battery. Was able to continue to our final destination approximately 15 minutes later and no more than 10 miles driven. Hybrid malfunction was still visible on the dash to include the warning stating that vehicle needed to go to the service department. Approximately an hour later, vehicle was turned on again with the same warning about the hybrid malfunction, however, engine started in electric. Drove vehicle to dealership and stated what happened. Dealership the next day stated that this was a phantom code known by Mazda, but no problems associated with the code. Vehicle picked up per service advisors request two days later. Mazda dealership stated that headquarters had eyes on this particular vehicle. A day later after the pick up Mazda dealership requested vehicle be brought back for a “DC box” repair. Dealership stated this process would take a week or thereabouts to replace this component. Vehicle currently in dealership service.
NHTSA complaint #11603677 — an unverified report by a vehicle owner.
I was driving 65 mph and the hybrid system malfunction warning came up. Car dropped to 25mph - pressing the gas pedal would not increase the speed. Continued to coast with no acceleration until it came to a stop and shut off
NHTSA complaint #11594863 — an unverified report by a vehicle owner.