NHTSA complaint #11730353

Owner complaint summary

My 2023 Mazda CX-5 (48,000 miles) is experiencing a loud mechanical whirring/grinding from the driver-side headlight assembly, a documented manufacturing defect involving foreign matter contamination of the internal LED cooling fan bearings (TSB 09-029/25). Despite the manufacturer acknowledging this factory-installed defect, Mazda has refused to proactively remedy the issue because the vehicle is nominally past its 36,000-mile bumper-to-bumper period. I have been explicitly advised by service personnel to continue operating the vehicle until the headlight unit 'entirely fails' before further assistance may be considered. This 'fail-first' directive is a reckless disregard for public safety; the internal cooling fan exists specifically to prevent the high-intensity LED from overheating. A failure of this fan leads directly to the sudden burnout of the main headlamp while the vehicle is in motion. Mazda is essentially requiring me to drive a vehicle with a known, ticking-clock lighting defect and wait for a total loss of visibility at night before they will address a part that was contaminated during their own production process. This is a critical safety hazard that places myself and other drivers at risk of a collision due to sudden headlamp failure.