2004 Mazda 6

The 2004 Mazda 6 was a popular mid-size sedan known for its sporty handling and stylish design. Available engine options included a 2.3L inline-4 engine producing around 160 horsepower and 150 lb-ft of torque and a 3.0L V6 engine producing around 220 horsepower and 192 lb-ft of torque. Transmission options included a 5-speed manual, 5-speed automatic (for the I4 and V6), and a 6-speed manual (for the V6). Owners generally appreciated the Mazda 6’s driving dynamics and aesthetics, but common complaints centered around rust, particularly in areas with harsh winters, and some reliability concerns.

Engine

2.3L Inline-4 Engine

• Timing Chain Tensioner Failure
  • Description/Symptoms: Rattling noise, especially on startup. Can eventually lead to engine damage if the timing chain slips.
  • Solution: Replace the timing chain tensioner.
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found
• Oil Leaks (Valve Cover Gasket/Timing Cover)
  • Description/Symptoms: Visible oil leaks, burning oil smell.
  • Solution: Replace the valve cover gasket or timing cover gasket.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found

3.0L V6 Engine

• Ignition Coil Failure
  • Description/Symptoms: Misfires, rough running engine, check engine light.
  • Solution: Replace the faulty ignition coil(s).
  • Estimated Cost to Fix: $100 - $300+ (per coil)
  • Recalls: None Found
• Vacuum Leaks
  • Description/Symptoms: Rough idle, poor performance, check engine light.
  • Solution: Locate and repair vacuum leaks. Replacing hoses and intake manifold gaskets.
  • Estimated Cost to Fix: $100 - $400+
  • Recalls: None Found

Transmission

5-Speed Automatic Transmission

• Slipping/Harsh Shifting
  • Description/Symptoms: Transmission slips between gears, harsh or delayed shifting, failure to shift.
  • Solution: In some cases, a fluid change can help. More severe cases may require a transmission rebuild or replacement.
  • Estimated Cost to Fix: $200 (fluid change) - $1500 - $3500+ (rebuild/replacement)
  • Recalls: None Found

Suspension

• Rust/Corrosion of Rear Subframe
  • Description/Symptoms: Excessive rust on the rear subframe can compromise its structural integrity, leading to clunking noises, poor handling, and potential failure.
  • Solution: Inspection and treatment of rust. In severe cases, subframe replacement is necessary.
  • Estimated Cost to Fix: $100 - $300+ (rust treatment), $800 - $2000+ (subframe replacement).
  • Recalls: None Found
• Worn Suspension Components (Control Arms, Bushings, Ball Joints)
  • Description/Symptoms: Clunking noises, poor handling, uneven tire wear.
  • Solution: Replace worn suspension components.
  • Estimated Cost to Fix: $200 - $1000+ (depending on parts replaced)
  • Recalls: None Found

Electrical

• Power Window Motor Failure
  • Description/Symptoms: Window does not go up or down, or moves very slowly.
  • Solution: Replace the power window motor.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Battery light on, dimming headlights, vehicle stalls.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Exterior

• Rust (Wheel Arches, Rocker Panels, Door Bottoms)
  • Description/Symptoms: Visible rust on various body panels.
  • Solution: Rust repair (sanding, filling, painting) or panel replacement.
  • Estimated Cost to Fix: $200+ per panel (rust repair), $500+ (panel replacement)
  • Recalls: None Found

Interior

• Dashboard Cracking
  • Description/Symptoms: Cracks appearing on the dashboard surface, particularly in sun-exposed areas.
  • Solution: Dashboard replacement or dashboard cover.
  • Estimated Cost to Fix: $100 (dashboard cover), $500 - $1500+ (dashboard replacement).
  • Recalls: None Found

Summary

The 2004 Mazda 6 is a generally reliable vehicle, but rust is a significant concern, particularly in regions with salted roads. Engine issues like timing chain tensioner failure (2.3L) and ignition coil failure (3.0L) can occur, and the automatic transmission may experience slipping issues. The suspension can also suffer from rust and worn components. The severity and cost of these issues vary, but addressing rust early is crucial to prevent more extensive and expensive repairs.