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Mazda6 Crack Noise


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#1 JBT

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Posted 16 July 2014 - 02:01 PM

I recently bought a one owner 2009 GH Mazda6 with 84,000km.

I'm starting to hate this car because of a loud random "crack" noise that it makes when going over some bumps sometimes. :banghead:

It sounds like the body is cracking or the suspension subframe is cracking or moving slightly.

The noise comes from the front footwell area on the left or right depending on which side is has taken the brunt of the bump.

It only happens on bump (suspension compression) and not rebound.

The suspension does not bottom out and the noise can happen at any speed from parking pace up to the legal limit.

Suspension deflection can be small to maximum.

It is very random and can happen in smooth dips or over sharper lumps in the road.

A trusted suspension specilaist has looked at it and reckons all is good. I agree from what I can see.

 

Has anyone else experienced this ot have a clue as to what it could be?


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#2 chief tool

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Posted 16 July 2014 - 06:09 PM

Could be a loose bolt somewhere, or a worn component like a stabiliser control link.

 

I would suggest a visual inspection. I had a similar problem on one of my 626s, a loud clunk. I though it was a loose strut (where it bolts into the tower bearing) but on visual inspection underneath two subframe bolts were half out from where the exhaust shop would have removed a part of it to replace the exhaust.

 

My work Ford Territory used to chew through stabiliser control links like there is no tomorrow. My 6 has the same kms as yours and isn't worn..but I don't know how long they last. They seem to be a bit of a weak point on some cars.

 

Otherwise one of the struts could be on the way out. 84kkm isn't much, but it depends what sort of driving the car has done in that time. I used to live in an area with alot of rough roads and it wasn't unusual to kill a set of front struts in 100kkm.



#3 JBT

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Posted 16 July 2014 - 08:29 PM

Thanks for the thoughts.

The car seems to have been used around town mostly and not thrashed.

Stabiliser bar end links all checked OK.

All other suspension components and attachments checked OK.

All subframe bolts etc. checked tight.

Driver's side and lower engine mounts replaced - they were stuffed.

 

This noise is a sharp "crack" noise and is completely random. It may not eventuate for days then, just when you least expect it, it'll go "crack" over some minor dip or lump. Other occupants in the car can hear it when it happens.

I've never heard anything like it before in 46 years of car ownership - and I've owned some pieces of shite in that time.


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#4 bgarry

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Posted 20 July 2014 - 05:13 PM

Hi JBT,

            I've got the exact same issue with my 2008 GH Luxury Sports (77,000km) and it's driving me nuts. Just had the top engine mount replaced and the noise is still there.

Going in for a service next week and i'm going to see if I can demonstrate the knock to a mechanic as I have no intention of continuously paying out for them to guess the root cause.

 

Brendan



#5 JBT

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Posted 20 July 2014 - 07:22 PM

G'day Brendan,

 

Well I'm glad I'm not alone.

 

I've talked about this issue with an old (yes aged and and very experienced) friend. He thinks it could be a spot weld that has let go, a chassis/subframe crack that is working, or radial crack(s) in the chassis/subframe where a captive nut(s) is(are) located.

 

Trouble is, it will be almost impossible to find the bluddy thing(s). If it was a crack you'd have to find it, stop drill it and relieve whatever is causing the crack to start.

 

Oh well. I'll put the POS on the car stands again next week and see if I can see anything - not holding out much hope though.

 

Oh, and although it has behaved itself for the last week, we went over a small dip in the local area today and "crack" there it was. Must have driven over that dip about eleventy thousand times and it has never done it there before. :banghead:

 

John


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#6 tezzas

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Posted 21 July 2014 - 07:08 PM

I recently bought a one owner 2009 GH Mazda6 with 84,000km.

I'm starting to hate this car because of a loud random "crack" noise that it makes when going over some bumps sometimes. :banghead:

It sounds like the body is cracking or the suspension subframe is cracking or moving slightly.

The noise comes from the front footwell area on the left or right depending on which side is has taken the brunt of the bump.

It only happens on bump (suspension compression) and not rebound.

The suspension does not bottom out and the noise can happen at any speed from parking pace up to the legal limit.

Suspension deflection can be small to maximum.

It is very random and can happen in smooth dips or over sharper lumps in the road.

A trusted suspension specilaist has looked at it and reckons all is good. I agree from what I can see.

 

Has anyone else experienced this ot have a clue as to what it could be?

My previous BK3 had the same noise in the front end,took it to the dealer (Dwyers Mazda) and explained the problem.

They released the tension on all the suspension components,then retorqued them to spec.

Voila!  noise gone and never came back.

Hope this helps you.



#7 JBT

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Posted 22 July 2014 - 08:27 AM

Interesting...and many thanks for that info.

Coincidentally, I released and re-tightened the rear subframe bracket bolts where they mount to the body yesterday. No noises on the subsequent test drive but that doesn't mean anything.

I might do likewise with the subframe to rear mounting bracket bolts and the lower control arm rear bush housing mounting bolts as well today.


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#8 JBT

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Posted 22 July 2014 - 02:50 PM

So I've done that today. Now all the nuts and bolts at the rear of the subframe and the lower control arm rear bush housing have been loosened and retorqued.

Let's see what happens now. :whistling:


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#9 JBT

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Posted 23 July 2014 - 11:29 AM

Well that was a fail! POS did it again today! I hate this car.


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#10 Bart

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Posted 27 July 2014 - 10:04 AM

G'day JBT and others,

 

I have a late 09 Luxury Hatch - having owned it since new. Towards the end of last year (approx Oct 13) I noticed the same noise from the front right side of the car when I was travelling over a particular section of road that has a slight undulating dip in it. I thought, 'what's that?'.  I thought 'did I go too fast over that uneven area?".

 

It is adhoc when it does occur.

 

I had the car checked by a reliable suspension specialist near where I live soon after hearing the noise. They advised me that all the components are fine in terms of struts etc. They could not account for the noise; nor repeat it during a test drive. 

 

At the moment my car has 68K on it; it's a fantastic car to drive. Just that little noise every now and then - I am actually glad to hear it's just not me imagining it! :)

 

I've wondered if it is the front right strut going; spring etc. It seems - in my case - to be isolated to the front right wheel. 

 

I'd love to hear if anyone gets a solution on it.

 

Tezzas: thanks for the info on the torquing to spec; I might get that checked on next service.

 

JBT: don't give up on the car due to the noise - there has to be a solution :). The GH is awesome - I am just miffed that Mazda has not made a hatch in the new model.... 

 

I will let you know how I go when I get it checked at next service - no due for a little while though.

 

 

I also note that someone also posted a similar concern here: http://www.ozmazda.c...new-suspension/

 

Cheers

 

Bart



#11 JBT

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Posted 27 July 2014 - 04:32 PM

I'm looking forward to hearing any info that cures this issue and your thoughts are appreciated too Bart. It's really annoying when it happens so randomly.

I had ours up on the stands again yesteday and looked for cracks or failed welds on the front subframe but couldn't find anything. I must admit that it looks like new under there.

 

We bought our M6 because it was the only "affordable" hatchback in that size car. I'm so disappointed in the lack of quality in this car that Mazda used to represent and I sometimes wish now we had gone with a dumb Camry/Aurion sedan.

I think the next car will be a used Lexus IS250 or IS350 - something reliable with quality and rear wheel drive. :yes:


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#12 Bart

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Posted 27 July 2014 - 07:47 PM

Hey JBT

When the suspension guys had my car up checking it all looked good as well. No cracks etc.

I read today something about tie-rods. Have you had yours checked? I am wondering if that could be a cause...... I.e out of spec and needing replacement.

I kept a keen ear out today while I was driving and there was no sound. Very random.

Cheers

Bart

#13 JBT

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Posted 27 July 2014 - 11:06 PM

Ken at Accurate Suspensions, whom I highly respect and trust, reckoned all was well with the suspension when he checked it a couple of months ago. He specifically noted that the tie rods and sway bar end links are all good. It all looks and feels new to me too.

 

Yes, no noises from mine today after driving over all sort of dips and speed humps but it "popped" yesterday over a small dip in our street...I didn't even know the dip was there until the car made the noise. Grrrr.


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#14 Bart

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Posted 28 July 2014 - 08:30 PM

Ken at Accurate Suspensions, whom I highly respect and trust, reckoned all was well with the suspension when he checked it a couple of months ago. He specifically noted that the tie rods and sway bar end links are all good. It all looks and feels new to me too.
 
Yes, no noises from mine today after driving over all sort of dips and speed humps but it "popped" yesterday over a small dip in our street...I didn't even know the dip was there until the car made the noise. Grrrr.



Damn.

#15 JBT

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Posted 29 July 2014 - 08:41 PM

Yeah damn...and the annoying thing is that it is so random that you can't demonstrate the noise over any particular road imperfection or lump as it may only happen once at that place.

 

Maybe it's an impending damper/spring problem. Such a shame on Mazda quality wise because the rest of the car is quite acceptable.


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#16 bgarry

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Posted 01 August 2014 - 08:15 PM

Just got mine serviced and mentioned the crack/knock noise to the mechanic .. He took the car for a test drive and heard the noise on the first speed hump he went over, he reveresed back and went over it a number of times more but could not get it to recoccur.

On inspection he found that the rubber on the rear engine mount was cracked  on both sides. I had the engine mount replaced today and so far have not been able to get the noise to reoccur but I guess time will tell.

 

 

I've attached some images of both side of the engine mount and hopefully you can see the issue.

 

 

http://s7.postimg.or...8b/IMG_1420.jpg

 

 

 

IMG_1420.jpg

 

 

http://s2.postimg.or...zt/IMG_1421.jpg

 

IMG_1421.jpg

 

 

Regards,

Brendan


Edited by bgarry, 01 August 2014 - 08:17 PM.


#17 JBT

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Posted 01 August 2014 - 08:55 PM

Thanks for that thought.

I replaced that mount plus the one on the driver's side about 2000km ago when I bought the car. Both are still OK.

It's pathetic that they fail at such low kms.

How many kms has your car done?


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#18 bgarry

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Posted 01 August 2014 - 09:29 PM

Mine has 78000km on it but if the nose was caused by this mount then it was gone at 65,000km



#19 Bart

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Posted 01 August 2014 - 10:04 PM

Brendan

Thanks for this information. I reckon mine started making the noise around 62K. I will get it checked out at the next service.

Cheers

Bart

Edited by Bart, 01 August 2014 - 10:05 PM.


#20 JBT

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Posted 02 August 2014 - 09:28 AM

It seems the Mazda6 and Mazda3 engine mounts have a habit of failing at around the 70,000 - 80,000km mark...which is pretty poor.

Two of the three mounts on my car have been replaced.

The noise in my car comes from the left or the right depending on which side was affected by a dip or bump so it's not an engine mount problem.

I'm beginning to wonder if the problem with mine it is "sticking" front shocks or a problem with upper front shock mountings.

I'm going to contact Grand Prix Mazda and Fulcrum Suspensions on Monday and see if they have any history on these cars and/or any advice regarding suspension noises.

 

.


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