What 403 owners told NHTSA about the 2024 Mazda Cx-90-phev

The lower fuel pump is going out. It is a known issue with the car. I was driving out of town and the car started to stall. My steering has become ruggish while on the trip as well, and steering was complicated during heavy winds. The car has been inspected by dealer and both warning lights have been cleared. But the issues still remain.

NHTSA ODI 11747228

My 2024 Mazda CX-90 PHEV Premium Plus has experienced repeated hybrid system failures. The vehicle currently has an active "Hybrid System Malfunction" warning light. This is the latest in a series of 17 recalls and recurring defects since purchase in July 2023. Most recently, the vehicle was out of service from February 14, 2026 to approximately March 18, 2026 due to a severe transmission fluid leak, which the dealer (Nealson Mazda Cool Springs, TN) acknowledged was common in this model. The current hybrid system malfunction warning poses a direct safety concern as it affects the vehicle's powertrain and reliability. I am a daily driver of this vehicle and have two young children who ride in it regularly.

NHTSA ODI 11741525

My 2024 Mazda CX-90 MHEV has experienced multiple life-threatening sudden engine stalls and a complete loss of motive power while driving in active traffic lanes. The first incident occurred on December 31, 2024, when the vehicle abruptly shut down with an "Engine Malfunction" dashboard alert. The vehicle was towed to an authorized Mazda dealership (Palatine, IL), where it was held for a week, but technicians stated they could not replicate the issue and returned the car to me as safe. On March 30, 2026, the exact same failure recurred. While driving, the engine suddenly shut off completely at a traffic intersection. After turning the vehicle off for 5 minutes, it was restarted and driven to another authorized Mazda dealership (Crystal Lake, IL) for specialized diagnostic scanning. The second dealership successfully retrieved stored diagnostic trouble code (DTC) P061B, which is directly linked to safety recall 24V-815 (Loss of Drive Power from Software Errors). Crucially, the detailed diagnostic scan revealed that this code was historically stored with a timestamp dating back to December 2024. This proves that the safety defect was active and detectable during the first dealer visit 16 months prior, but was completely missed by the first dealership, leaving my family with an ongoing crash hazard. To address the failure, the dealership replaced the low-pressure fuel pump in the fuel tank and a mass airflow (MAF) sensor. However, Mazda Corporate customer experience has formally stated to me in writing that they are "not in a position to guarantee the concern will not reoccur." Because this safety-critical propulsion failure causes the vehicle to suddenly die in traffic and has a documented history of ineffective recall remediation, it poses an unresolved, severe crash risk. The vehicle is currently in my possession and available for inspection.

NHTSA ODI 11737446

The fuel tank pressurization systems on my 2024 Mazda CX-90 PHEV have failed, and the vehicle is currently available for inspection at Dolan Mazda in Reno. This defect puts the safety of myself and others at risk because the vehicle gurgles and sprays raw gasoline out of the filler neck during refueling, creating a severe fire and environmental hazard at public gas stations. The issue first appeared on March 23, 2026, during a road trip from Reno to Las Vegas, with dashboard warnings stating Fuel Tank Malfunction, Avoid Refueling, Have the vehicle inspected and Engine Malfunction. The vehicle was inspected and supposedly repaired by Jerry Seiner Mazda on March 24, 2026, but the problem recurred during the return trip from Las Vegas to Reno on March 29, 2026, when it again spit fuel at the pump. The failures consistently occurred midway through long road trips at refueling stops in Tonopah, Beatty, and Hawthorne, Nevada. During these incidents, the vehicle was completely unable to accept fuel, causing significant distress as I was nearly stranded with young children in remote desert areas with limited resources. I barely managed to reach my destination on the remaining range. Although I have documented these specific malfunction messages and safety incidents, the vehicle has been at Dolan Mazda since April 17, 2026, where the dealer and manufacturer have been unable to reproduce the issue in a stationary shop environment despite it being the second formal repair attempt for a life-threatening fuel system failure.

NHTSA ODI 11733436

After multiple visits to the dealer—and despite a manufacturer recall addressing the issue of remaining fuel levels and estimated range—the error message has reappeared.During my most recent visit to the dealer, I was informed that they could not detect any errors.

NHTSA ODI 11731716

We believe the evaporative emissions control system (EVAP) / fuel vapor management system on our 2024 Mazda CX-90 MHEV (inline-6 mild hybrid) is malfunctioning, releasing strong raw gasoline vapors. The strong odor occurs everywhere around the vehicle while the engine is running and immediately after shutdown and exit. The problem is intermittent. No visible liquid fuel leaks have been observed. The vehicle and related components remain available for inspection upon request. This creates a direct safety risk: the hazardous flammable gasoline vapors are strong enough to migrate from our garage into our living space (house), posing a potential fire/explosion hazard if vapors accumulate near an ignition source, as well as a health concern from prolonged inhalation for our family. Raw gasoline vapors are highly flammable and should not be present in or around a residence. The problem has been reproduced and confirmed by the dealer on at least one occasion. On the third service visit (dropped off March 5, 2026), the strong raw gasoline odor was so intense upon arrival that multiple dealership personnel, including General Manager Weldon Munsey, witnessed it immediately, and one technician looked under the vehicle to check for liquid gasoline leaks. On the two prior visits, technicians were unable to replicate the issue. The local dealer has informed us that they are aware of two other CX-90s with the exact same problem occurring at the same time within their dealership network. Despite having no root cause, no fix identified, and no timeline for resolution, the dealer wants us to return the loaner and take our car home unrepaired. The vehicle was purchased new on [XXX], and currently has 39,213 miles. It has been inspected multiple times by the dealership (Roger Beasley Mazda Georgetown, repair order [XXX]). Mazda Corporate has an open investigation (their case [XXX]) and has assigned a case manager (Chris) who is currently reviewing the issue with the service INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11730940

While my wife was driving my 2024 Mazda CX90 gas turbo at the posted speed limit, this vehicle suddenly without warning the car lost most of its power. She was able to move the vehicle to safety by pushing the gas pedal to the floor and achieved a maximum speed of 10 mph. The car was towed to the dealer Koch 33 of Easton, PA. The dealer diagnosed the problem as a throttle body issue. This is the second incident whereby this vehicle lost power in a similar manner but for a different reason (fuel pump) and had to be towed to the same dealer. I filed a complaint with your agency about 18 months ago. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11730463

The authorized dealer, Cochran Mazda, previously bypassed the vehicle’s hybrid system and returned the vehicle to us stating it was safe to operate and that we could disregard warning messages until a replacement hybrid battery became available. Prior to this, we had reported repeated drivability concerns, including jerking during operation. We were advised that this behavior was normal for hybrid vehicles. While awaiting a follow-up service appointment, the vehicle displayed a “Critical Engine Malfunction” warning and experienced a significant loss of power while traveling across the Liberty Bridge in Pittsburgh, PA. The vehicle would not accelerate beyond approximately 15 mph and then stalled out on the bridge. We activated hazard lights and were able to proceed slowly to a nearby parking lot, where the vehicle required towing. This incident created a hazardous traffic condition and raised significant safety concerns.

NHTSA ODI 11720818

Upon starting the vehicle, on the dash there was a message "hybrid system malfunction" as well as "engine malfunction have the vehicle inspected". Upon driving it home, the same message appeared 10/24/25 as of today when the car starts now the only message that remains is "engine malfunction have the vehicle inspected" I have an appointment at Mazda on 10/30/25 for the vehicle to be inspected. This vehicle has already been taken to this location for two recalls. Today 10/26/25 I looked up my vin for any new recalls and there is an additional recall. Manufacturer Recall Number7825I NHTSA Recall Number25V-568 Summary When fuel containing ethanol is used, it may react with materials on the sending unit circuit board in the sub-tank. This reaction can create a buildup that interferes with the gauge function that may cause the display on the instrument cluster to read an incorrect fuel level. Safety Risk If the vehicle incorrectly indicates an inaccurate fuel level, there is a risk of running out of fuel while driving. This would result in an engine stall and the vehicle cannot be restarted, increasing the risk of a crash.

NHTSA ODI 11695692

I bought a brand new 2024 CX90 in May 2025. I was on the on-ramp entering a Highway at an accelerating speed when the car all of a sudden went into a limp mode and was unable to accelerate. This limp mode that kicked in almost caused me to be hit from behind. Immediately on the dash it flashed Engine Malfunction. I had to pull over to the side of the highway and had the car brought to my local Mazda Dealer. My local Mazda dealer stated that the recent recall #25V-568 NTSHA caused the program/software for the car to misread my fuel pump and essentially burned out my fuel pump, and therefore breaking my fuel pump. They said they called Mazda, and Mazda is denying the fix because there is "no release date". Since Mazda is refusing to fix this, my local dealer says I have to drive the car as is. However, this is unsafe to drive. I paid for a brand new car only for it to have tech issues with Mazda refusing to do any fixes. This is our family car and I drive around with young kids. This is very unsafe to drive and Mazda needs to remedy this siutation immediately.

NHTSA ODI 11686926

Decelerating behind traffic my Mazda cx90 shut the engine down. While still rolling traffic began to accelerate and I pressed the accelerator. The engine did not restart. I bottomed out the pedal with no reaction. I completely removed pressure from the pedal then pressed again before the engine restarted. This vehicle has already had a recall repair that seemed to be for this issue

NHTSA ODI 11680502

Received Hybrid Battery Malfunction and Electrical Leakage Detection alerts two weeks ago. Dealer has not been able to fix. First they said it was the water heater, then they said my radiator was leaking and I need a new one. Estimated 4 additional weeks for repair.

NHTSA ODI 11644305

The fuel gauge and range indicator are faulty. I was doing long-distance highway driving during the holidays. At 1/4 tank, the range indicator said 110 miles until empty. As soon as the needle dipped a fraction below 1/4 tank (about 20 miles later) the range indicator dropped instantly to 40 miles left AND THEN DROPPED ONE MILE PER SECOND UNTIL IT REGISTERED ZERO. The needle also fell at the same rate until I was driving on the interstate with zero range and a gas gauge buried below empty. All of this occurred within one minute. I pulled into the nearest gas station and filled up with 12.71 gallons (it's an 18.5 gallon tank). So I actually had 5.79 gallons left (or 156.33 miles of range at 27mpg on the highway). Not being able to rely on the gas gauge/range indicator is a safety issue.

NHTSA ODI 11633686

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 ODI 11623076

I was traveling at 40mph on August 14 when the engine stopped running suddenly and without warning. I lost all power. I tried pressing the gas pedal and the engine shuddered and sputtered with the speed ranging from 0 mph to about 18mph with no steady duration longer than a second or two. At the same time an engine icon appeared and a message displayed reading engine malfunction. I safely exited the travel lane despite having very little power. I waited 10 seconds and restarted the car and everything worked fine. I called the dealer explained the incident and to made arrangements to have the vehicle serviced. The appointment was for Friday. When I asked whether I should continue driving the car. I was told that so long as the engine icon was not flashing the car was ok to drive. The next day I started the car and did not see any warning message or engine icon. I thought all was ok so I cancelled the appointment. A second incident occurred later in the morning. I called the dealer again and was told to bring the car in that afternoon, Thursday. On the way over to drop off the car a third incident occurred with the same characteristics as the first two. Each time waiting 5 to 10 seconds restored power to the car. One week later the car was returned to me with the diagnosis of low fuel pump pressure problem. I am wary of driving this car on any trip especially on a speed highway for fear this situation will occur when I am driving at 70mph. I appreciate your taking the time to read this description of a very scary and unnerving situation that no one should face.

NHTSA ODI 11610478

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 ODI 11604822

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 ODI 11594863

4 weeks ago my wife was driving on a busy highway and lost propulsion. Hybrid System malfunction message. She was able to pull over before causing an accident and put the car in gas only mode. She never shut the car off and drove on to her destination. I met her and picked up the car and took it to the dealer. Car is new and has 5000 miles on it. Car has been at dealer for 4 weeks with no answers and several unanswered phone calls to customer service at Mazda Corporate. Been told that is is a software problem with no fix and no time frame of when there will be a fix. I do have a case number with Mazda. Today after threatening calls to invoke "Lemon Law" in my state Mazda has suddenly said that the car has a faulty inverter and that the part is available and will be replaced. My feeling is that they are just throwing parts at a problem. This car is unsafe and NHSTA should put pressure on Mazda to either resolve issue or buy back cars. The majority of the complaints listed here are the same. Please take action!!

NHTSA ODI 11594049

Gas door stuck closed

NHTSA ODI 11589395

On several occasions vehicle while in EV mode has lost all propulsion at highway speeds creating an unsafe condition.

NHTSA ODI 11587861

At highway speeds on a few occasions when traffic I slowing vehicle appears to continue to accelerate for 1-2 seconds after removing foot from accelerator almost causing accident since traffic ahead is slowing.

NHTSA ODI 11587863

Car suddenly, unexpectedly, and without warning lost power while driving putting us at risk for serious collision/injury with inability to drive the car and then gave "Hybrid System Malfunction" warning. This occurred AFTER performing the recall which was supposed to address this issue.

NHTSA ODI 11584563

At 3200 miles the vehicle had a major powertrain malfunction causing the vehicle to throw multiple error codes - Hybrid System Malfunction; Charging System Malfunction; Electrical Leakage Detected. Was instructed to pull over to a safe area immediately. Was unclear how long car would continue to be drivable. Once car stopped it became completely immobile. Repeated restart attempts would not let vehicle start ICE engine or shift into gear. Had to be towed via dollies to nearest dealer for diagnosis and repair. Dealer found a failed PTC heater unit as source of problem and replaced it (Mazda part- KMV6-61-FHX). Vehicle is once again drivable, but the dealer has no idea what would cause the unit to fail and how to avoid future problems. Dealer has heard about this with many vehicles and repaired several similarly. We are fortunate to have found a safe place to pull off the road before powertrain shutdown, but if not we would have been stuck on the road with no ability to move the vehicle and occupants to safety. I hope NHTSA can investigate whether a recall of that part or the software that controls it is needed. NHTSA should also look into the failure mode of the vehicle to see if a different approach is safer and more appropriate.

NHTSA ODI 11577948

There has been two dangerous failures both occurring in an intersection. First instance was in December of 2023 whey the fuel pump failed while turning in an intersection. The second incident was a hybrid battery malfunction, rendering my vehicle unusable in the middle of an intersection again. This was 03/2023

NHTSA ODI 11577123

What component or system failed or malfunctioned, and is it available for inspection upon request? "Hybrid System Malfunction. Stop Vehicle in a Safe Location." Car completely inoperable. Had to tow to dealership as would not start or go out of park. Hybrid and High Voltage battery issues reported by multiple owners. This happened less than a month into owning the vehicle and with less than 1200 miles. How was your safety or the safety of others put at risk? Car deceleration on highway specific to this error reported by multiple owners. Has the problem been reproduced or confirmed by a dealer or independent service center? Uknown. Currently being serviced by dealer. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Currently being inspected by the Mazda dealership I leased the vehicle through. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? "Yes, just a week into having the vehicle (at 300 miles) a "Hybrid System Malfunction" error message appeared to "Have the Vehicle Inspected." Dealership had it in their Service shop for over 2.5 weeks and said nothing was wrong with it.

NHTSA ODI 11567596