My Mazdaspeed CAI broke...

[Dan Da Man]

So i had my engine light on... Every few months this happens to me. Car bogs and sputters and I bring it to Mazda and they fix it under warranty. This time was a little different. Mazda had to hold my car for a day for parts, So i call the next day and ask what's going on with the car. New news, Im told by service that my CAI is broken... the metal hinge near the bottom broke off and there's a hole. They are not able to fix it. So my options are.... By a new intake with installation for 600 plus bucks or bring in my stock box and they put it together for me. So i pick option two, head to the dealer and check out my finely crafted intake. Made me laugh to see a hole in the bottom where the hinge thing screws into the car for support. it was completely broken off from the welds that hold it together. Did the dealership do it? i'll never know. I don't think so though, they treat me pretty good.

and of course there is no warranty on the part since its been on the car for over 2 years.

So my car does not sound as awesome as it did and makes more, kind of boring now, all i hear is the rusted out clanging exhaust.

Anyone else have this problem?

And what's the lesson i learned?

Mazdaspeed parts are crap, the exhaust rusts out after one winter and the CAI was crafted by monkeys.

So 2 out of 3 Mazdaspeed dealer bought parts are dead on my car... I have the short shifter as well.. wonder how and when it will break.

[cwp_sedan]

That sucks. I haven't had that issue at all. That is pretty messed up though. When did you install it?

Why wouldn't you just buy one ind install it yourself. $600 is a joke. You can easily cut that cost in half by installing it yourself.

[Dan Da Man]

Why buy another one? So it can break. F that.

[Thrizzl3]

Mazdaspeed FTL..

[cwp_sedan]

Why buy another one? So it can break. F that.

I didn't actually say get MS did I. Get something else then, or don't.

[dreadlock]

Ouch rought news man, sorry to hear.

How far down is the hinge that broke? I wouldn't mind looking at mine to see the condition if possible, I bought the car with the CAI installed so not all that familiar with it yet...

[mazdaskit]

Man that sucks... but i think NextMod has cai on sale for like 120 right now maybe look into it..

[RedRaptor]

Any pics of the damage?

I've had my MS CAI for 3 years now and no issues with it at all. The only thing that happened was the damper that connects the hinge to the car has snapped off. I've zipped tied it to keep it from vibrating too much but its been like this for 2 years.

[pt109]

So my car does not sound as awesome as it did and makes more, kind of boring now, all i hear is the rusted out clanging exhaust.


Concerning the sound of your car, perhaps you could get something like a
SRI from Cosmo or PRM, for a lot less than $600 (thats downright insulting!).

Install seems much easier, and your car would probably sound just as good as with your CAI.

[Mazda3X2]

Why not get your MS CAI welded? That's what I would do.

There are a lot of metal shops around, although finding one that can weld aluminum may be a challenge. A 1/2 hour, a phone, and the yellow pages could be worth it.

And +1 to other comments about the $600. If you get something else, install it. There are always instructions and "how-to" videos / write-ups on the net if you aren't exactly mechanically inclined.

Best of luck.

[tweak_s]

Why not get your MS CAI welded? That's what I would do.

There are a lot of metal shops around, although finding one that can weld aluminum may be a challenge. A 1/2 hour, a phone, and the yellow pages could be worth it.

And +1 to other comments about the $600. If you get something else, install it. There are always instructions and "how-to" videos / write-ups on the net if you aren't exactly mechanically inclined.

Best of luck.

Well keep in midn the 600 is what the dealer quotes..even an MS CAI/intake whatever, can be installed for much less (if one doesn't want to DIY) elsewhere. Its just dealer premium, and also its supposed to (keyword supposed to) maintain warranty.

[Donutz]

Why not get your MS CAI welded? That's what I would do.

I was going to suggest the same thing! I can't see any place charging more than $25 for this (and that would be on the higher side of prices).

[Dan Da Man]

I never though of welding it..... Im going to upload some photos when i have time.

[RNUOVR]

had the samething happen to my AEM this weekend, it could easily be welded, but for my case I had to have it fixed yesterday and couldn't track doen any for my 2 buddies that are able to weld aluminum (& have the welder at home) - I fixed it with some JB weld and a hose clamp - I really wasn't inpressed on how crappy the aluminum of the CAI was - especially with how much they sell these for new. I'm planning on changing intakes now anyway (once a part fials on my I black list that company and switch brands). At least now I will have an AEM SRI to use this winter as I will cut it down once I get my new intake.

[axelaR]

This happened to one of the members on the BC forum: http://www.bcmazda3.com/forum/index.php?topic=8961.0

Except his was only 2 weeks old...and mazda did NOT warranty it.

Also, from what I've read in the past, the AEM intake is the exact same as the MS intake...AEM makes them for Mazda and it gets rebadged so this may be an issue with their design.

[iGOzoom]

that sucks!

[TheWulf]

I've seen several people have this problem with this intake.

IMO replace it with a better intake or it's likely to happen again.

[phoenix_bladen]

Hey guys, i know this thread is really old but the same thing happened to my intake as well. It's amazing how searching up I realized how others had the same problem.

The mazdaspeed intake really isn't good quality, an intake mount should NOT break after a few years, I got mine since 2007 but still.... these things really should last a long time.

I am not even sure what cause the mount to break... Corrison?

[r4BBiT]

I don't know where the CAI bracket is mounted, but I'm going to say vibrations and (moving) twisting of the engine.

[RedRaptor]

From what I have seen the break happens near the end of the intake where there is a rubber mount to the car chassis via bolt & nut.

The bolt & nut of the rubber mount usually seizes due to corrosion and will either rip the intake apart or strip off the chassis side. Mine stripped off the chassis side and Jimmy had to use his welding tool to free it.

I bought a replacement mount (under $5 part) and had Jimmy secure the CAI again.

[SomeGuy]

It's from the movement of the engine (which is a lot with the stock motor mounts) and a fixed point on the chassis where the bottom of the CAI mounts. Excessive movement causes the metal to fatigue and eventually break.

[Nick]

Zipties, 2 of them in opposite directions with enough slack for a little engine movement

[cwp_sedan]

I've had about 3 of these things go on me. I've left it all winter and can constantly here it vibrating while I'm stopped at lights or when going over bumps.

At times I've thought about putting the stock box back in.


Also for those questioning the quality of this intake, it is good. I've never had any issues except for this mount. The performance of it has always been good. AEM is at fault for this, not Mazda.

Unfortunately AEM has never updated the mount to work better.

[Flagrum_3]

Had my MazdaSpeed CAI Since I think '05 never an issue whatsoever....Maybe guys are tightening the mounts too tight? And /or NOT spraying your bolts with rust inhibitor...I do every year....all bolts under the hood....Who knows?

[cwp_sedan]

Had my MazdaSpeed CAI Since I think '05 never an issue whatsoever....Maybe guys are tightening the mounts too tight? And /or NOT spraying your bolts with rust inhibitor...I do every year....all bolts under the hood....Who knows?

The adhesive or whatever it is that holds the bolt to the rubber lets go. That or it gets pulled out of the rubber.

The bolt never breaks it just comes apart.

[Flagrum_3]

The adhesive or whatever it is that holds the bolt to the rubber lets go. That or it gets pulled out of the rubber.

The bolt never breaks it just comes apart.

Oh, very odd!

[suparobg]

strange