Mazda CX-90
Plug-in hybrid based on the 2.5L SkyActiv-G with two electric motors and 241 kW system output. Acceleration is impressive, but early software struggled: drive power loss in EV mode, defective 48V batteries, and multiple recalls defined the first model years. 2025 units are substantially more stable after the recall software updates.
PHEV With a Rough Start — Strong Drivetrain Underneath
241 kW system output and electric commuting range sounds compelling — and the CX-90 PHEV genuinely pulls hard. Early model years struggled with battery failures and drive power loss. Newer 2025 units are substantially more reliable after the recall fixes.
Engine Weaknesses 2
Multiple NHTSA recalls affect the CX-90 PHEV: faulty PCM/ECM software can cause sudden loss of drive power in EV mode. Campaigns 6323J, 7024J, and 7124J collectively affect over 150,000 MY2024–2025 vehicles. Mazda performs free software updates at dealers.
Symptoms: Multiple warning lights at startup, vehicle enters limp mode, drive power drops out in EV mode, vehicle fails to restart after i-Stop
Several CX-90 owners report 48V lithium battery failures between 20,000–40,000 km. Replacement parts ship from Japan and lead to wait times of several months. Affected vehicles often sit at the dealership for weeks.
Symptoms: Hybrid System Malfunction warning, vehicle stalls or suddenly loses drive power, multiple simultaneous warning lights
Vehicle Weaknesses 7
NHTSA recall 24V022 (Mazda campaign 6524A) affects 43,454 MY2024 CX-90 units: an assembly defect in the steering worm gear can cause sudden loss of power steering assist. Mazda replaces the spring engaging the worm gear and regreases the gear teeth. NHTSA opened a follow-up investigation into whether the fix was durable.
Multiple US class action lawsuits (2024–2026) document CX-90 brake pads wearing out and squealing within the first 1,000 miles. The lawsuits allege a fundamental design defect in the braking system. Mazda acknowledged the issue in a Service Alert (SA-016/24) but has offered no permanent fix. Vehicles relapse after warranty repairs.
Three simultaneous NHTSA recalls (Dec 2024) collectively cover 150,000+ vehicles: 7124J (Dash ESU — defroster/camera/cooling disabled), 7024J (PCM/ECM — drive power loss in EV mode), and a separate i-Stop recall. All remedies are free software updates at Mazda dealers.
38,926 MY2024 CX-90 units are affected: the auto start-stop system (i-Stop) can fail to restart the engine after an idle stop. Mazda reprograms the PCM and BECM with improved software.
CX-90 owners report early failures of the 48V lithium battery, sometimes at just 20,000 km. Replacement parts must be shipped from Japan, causing wait times of up to 4 months. Vehicles typically sit at the dealership for weeks.
A US class action lawsuit (2025) alleges the CX-90's Lane-Keep Assist System (LKAS) applies forceful steering corrections in the wrong direction, forcing drivers to fight against the wheel. A sudden assist cut-out can cause loss of control. Affected model years: 2024–2026.
The CX-90 is widely considered to have the thinnest paint in its segment — owners report scratching the clear coat with a fingernail. Rhodium White and some early production vehicles showed factory paint defects including dull patches and uneven base coat coverage. Mazda has not confirmed a permanent solution.
