NHTSA complaint #11736447

Owner complaint summary

My 2022 Mazda CX-5 Signature began producing a loud whirring/rattling noise from the driver-side front headlight assembly. After investigation, the noise was identified as coming from the internal cooling fan located inside the LED headlight unit. The cooling fan, which is integrated into the bi-LED headlamp assembly, appears to be failing prematurely due to bearing wear. This is a known widespread defect on 2019–2023 Mazda CX-5 models. Mazda has already issued Technical Service Bulletin (TSB) 09-015-23, which acknowledges the noise issue and instructs dealers to replace the entire front combination light assembly under warranty. However, no formal recall has been issued. The root cause appears to be Mazda’s design decision to use the full LED headlight beam as the Daytime Running Light (DRL), which keeps the headlight cooling fans running continuously whenever the vehicle is in operation — even in daylight. This accelerates fan bearing wear far beyond normal expectations. The headlight assembly costs $1,200–$1,700 per side to replace out of warranty. Owners whose warranty has expired are facing repair bills of $2,400–$3,400 for both sides. This constitutes a significant safety risk as headlight failure reduces nighttime visibility. I have scheduled a warranty repair at an authorized Mazda dealer under TSB 09-015-23.