🔧 Fusion - Front Brake Pads & Rotor Replacement

You’ll remove the front calipers, replace the brake pads, and swap the rotors on both front wheels. Worn pads and warped/thin rotors can cause noise, vibration, and longer stopping distances, so doing them together is the cleanest fix.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

---

⚠️ Safety & Precautions

• 🛑 Support the car with jack stands; never rely on a jack alone.
• 🧤 Wear gloves and safety glasses; brake dust and cleaner are irritating.
• 🔥 Brakes can be hot; let everything cool before touching.
• ⚡ Your Fusion is a hybrid—avoid touching any orange high-voltage cables. This job stays at the wheels and does not require HV service.
• 🧪 Brake fluid damages paint; wipe spills immediately.
• 🔋 Battery disconnect is not required for front brakes on your Fusion.

---

🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• 19mm socket
• 1/2" drive breaker bar
• 1/2" drive torque wrench (20-200 Nm range)
• 13mm socket
• 18mm socket
• Ratchet (3/8" drive)
• Socket extension (3"–6")
• Torx T30 bit
• C-clamp (6" minimum)
• Brake caliper hanger hook
• Wire brush
• Flat-blade screwdriver
• Bungee cord
• Safety glasses
• Nitrile gloves

---

🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front brake pad set - Qty: 1
• Front brake rotors - Qty: 2
• Front brake hardware/clip kit - Qty: 1
• Brake caliper grease (silicone) - Qty: 1
• Brake cleaner - Qty: 2 cans
• Brake fluid (DOT 4 LV) - Qty: 1 quart

---

📋 Before You Begin

• 🧭 Park on level ground, put the shifter in P, and set the parking brake.
• 🪵 Place wheel chocks behind the rear tires.
• 🧴 Open the hood and locate the brake fluid reservoir. Make sure it isn’t overfull—pushing pistons back can raise the level.
• 🧰 Lay out parts for one side at a time so left/right pieces don’t get mixed.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the front wheel lug nuts

• Use a 19mm socket and breaker bar to loosen the lug nuts about 1/2 turn (don’t remove yet).

Step 2: Lift and support the front of the car

• Lift with a floor jack (rated 3-ton minimum) at the proper front jacking point.
• Set the car onto jack stands (rated 3-ton minimum).
• Give the car a gentle shake to confirm it’s stable.

Step 3: Remove the wheel

• Use a 19mm socket and ratchet (3/8" drive) to remove lug nuts, then remove the wheel.

Step 4: Remove the caliper (the clamp that squeezes the pads)

• Turn the steering wheel to give yourself more room at the caliper.
• Use a 13mm socket and ratchet (3/8" drive) to remove the caliper slide bolts (the smaller bolts on the back of the caliper).
• Lift the caliper off the bracket.
• Hang it using a brake caliper hanger hook or bungee cord.
• Never let the caliper hang by the hose.

Step 5: Remove the old pads and hardware clips

• Pull the pads out by hand. If stuck, use a flat-blade screwdriver gently.
• Remove the stainless hardware clips from the bracket.

Step 6: Remove the caliper bracket

• Use an 18mm socket, breaker bar, and socket extension (3"–6") to remove the two caliper bracket bolts.
• Set the bracket aside.

Step 7: Remove the rotor

• If equipped with a rotor retaining screw, remove it using a Torx T30 bit and ratchet (3/8" drive).
• Pull the rotor off. If it’s rust-stuck, reinstall 1-2 lug nuts finger-tight and wiggle/pull the rotor straight off.

Step 8: Clean the hub and install the new rotor

• Use a wire brush to clean rust from the hub face (where the rotor sits).
• Spray both sides of the new rotor with brake cleaner and wipe dry (removes shipping oil).
• Install the new rotor. If there was a retaining screw, reinstall it with the Torx T30 bit.

Step 9: Reinstall the caliper bracket

• Position the bracket and start both bolts by hand.
• Tighten with an 18mm socket and torque wrench (20-200 Nm range).
• Torque to 115 Nm (85 ft-lbs)

Step 10: Install new hardware clips and pads

• Snap in the new hardware clips (from your hardware kit).
• Apply a thin film of brake caliper grease (silicone) where the pad “ears” slide on the clips.
• Install the new pads into the bracket.
• Grease only metal-to-metal slide points.

Step 11: Compress the caliper piston

• Place an old pad against the piston face.
• Use a C-clamp (6" minimum) to slowly push the piston back until it’s fully seated.
• Check the brake fluid reservoir level as you compress—do not overflow.
• Slow pressure prevents seal damage.

Step 12: Reinstall the caliper

• Set the caliper over the new pads.
• Install the slide bolts using a 13mm socket and torque wrench (20-200 Nm range).
• Torque to 25 Nm (18 ft-lbs)

Step 13: Reinstall the wheel

• Install the wheel and hand-thread all lug nuts.
• Lower the car off the jack stands using the floor jack.
• Tighten lug nuts in a star pattern with a 19mm socket and torque wrench.
• Torque to 150 Nm (111 ft-lbs)

Step 14: Repeat on the other front wheel

• Do the same steps on the other side. Front brakes should be replaced in pairs.

---

✅ After Repair

• 🦶 With the car on the ground, pump the brake pedal slowly 8–12 times until it feels firm (this seats the pistons against the pads).
• 🧪 Check brake fluid level and top off with DOT 4 LV only if needed.
• 👂 Start the car and confirm there are no warning lights related to braking.
• 🛣️ Perform pad bedding (break-in): make 6–10 medium stops from 30 mph down to 5 mph, allowing 30–60 seconds between stops to cool slightly. Avoid hard panic stops for the first 200 miles.
• 🔍 Re-check lug nut torque after 25–50 miles using a torque wrench.

---

💰 DIY vs Shop Cost

Shop Cost: $450-$850 (parts + labor)

DIY Cost: $160-$380 (parts only)

You Save: $290-$470 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-3 hours.

---

🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.