🔧 Fusion - Rear Brake Pad Replacement

Replacing the rear brake pads means removing the rear wheels, swinging the rear calipers out of the way, swapping the pads and hardware, then compressing the caliper pistons so everything fits back together. The key is handling the parking brake system correctly so you don’t damage the rear calipers.

Difficulty Level: Intermediate | Estimated Time: 1.5-3 hours

Assumption: Your Fusion has the electronic parking brake (EPB); steps include both EPB and non-EPB paths.

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⚠️ Safety & Precautions

• 🛑 Work on a flat surface; support the car on jack stands, not the jack.
• 🛑 Never press the brake pedal with a caliper removed; the piston can pop out and leak fluid.
• 🛑 If equipped with EPB, put it in service/maintenance mode before retracting pistons, or you can damage the parking brake motors.
• 🛑 Keep brake dust off your lungs; use brake cleaner instead of compressed air.
• 🛑 No hybrid high-voltage work is required for this job; keep tools away from orange HV cables anyway.

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🔧 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
• 21mm socket
• 3/8" drive ratchet
• 1/2" drive breaker bar
• Torque wrench (20-200 ft-lbs range)
• 7mm hex bit socket
• 13mm socket
• 15mm socket
• Flat trim/pry tool
• Bungee cord
• Brake caliper piston compression tool (specialty)
• Wire brush
• Brake cleaner spray
• Nitrile gloves
• Safety glasses
• Scan tool with Ford EPB service mode (specialty)

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake pad hardware/clip kit - Qty: 1
• Brake caliper grease (silicone) - Qty: 1
• Brake cleaner - Qty: 1

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📋 Before You Begin

• Park on level ground, turn the car OFF, and set wheel chocks at the front wheels.
• Loosen the rear lug nuts 1/2 turn using a 21mm socket and breaker bar before lifting.
• If your Fusion has EPB (parking brake button), use your scan tool to place EPB in service/maintenance mode. (This retracts the parking brake motors.)
• If your Fusion does not have EPB (foot pedal parking brake), make sure the parking brake is fully released.
• Open the hood and check the brake fluid reservoir level. If it’s near “MAX,” be ready for a small rise when pistons are pushed back.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and secure the rear of the car

• Use a floor jack to lift the rear at the approved jacking point, then place jack stands under solid support points.
• Confirm stability by gently rocking the car before removing wheels.

Step 2: Remove the rear wheels

• Remove the lug nuts with a 21mm socket and ratchet, then remove both rear wheels.

Step 3: Put EPB in service mode (EPB-equipped only)

• Use a scan tool with Ford EPB service mode (specialty) and run the EPB “Maintenance/Service Mode” function.
• EPB motors must retract before piston compression.

Step 4: Remove the caliper and support it

• Locate the rear caliper slide pin bolts on the back of the caliper.
• Use a 7mm hex bit socket with a ratchet to remove the two slide pin bolts.
• Carefully lift the caliper off the bracket using a flat trim/pry tool if needed.
• Hang the caliper from the suspension spring/arm with a bungee cord (do not let it hang by the brake hose).
• Torque on install: Torque to 25 Nm (18 ft-lbs)

Step 5: Remove the old pads and hardware

• Pull the inner and outer pads out of the bracket by hand.
• Remove the stainless hardware clips from the bracket using a flat trim/pry tool.

Step 6: Clean and prep the bracket

• Spray the bracket pad lands with brake cleaner spray.
• Lightly clean rust from the pad lands using a wire brush.
• Install the new hardware clips (they should snap in flat).

Step 7: Compress the caliper piston

• Position the old inner pad against the piston, then use a brake caliper piston compression tool (specialty) to slowly push the piston straight back into the caliper.
• Go slowly and watch the brake fluid reservoir level under the hood.
• Slow compression helps protect seals.

Step 8: Lubricate contact points and install new pads

• Apply a thin film of brake caliper grease (silicone) to pad ears where they touch the hardware clips (do not get grease on pad friction material).
• Install the new inner and outer pads into the bracket.

Step 9: Reinstall the caliper

• Lower the caliper over the new pads.
• Install the slide pin bolts using a 7mm hex bit socket and ratchet.
• Torque: Torque to 25 Nm (18 ft-lbs)

Step 10: Repeat on the other rear side

• Repeat Steps 4–9 on the other rear wheel.
• Always replace pads on both rear wheels.

Step 11: Reinstall wheels and torque lug nuts

• Reinstall wheels and hand-start the lug nuts.
• Lower the car off the jack stands using the floor jack.
• Torque lug nuts in a star pattern using a torque wrench: Torque to 135 Nm (100 ft-lbs)

Step 12: Exit EPB service mode (EPB-equipped only)

• Use the scan tool with Ford EPB service mode (specialty) to command EPB out of maintenance mode.

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✅ After Repair

• With the car still in Park, pump the brake pedal 10–15 times until it feels firm (this seats the pads to the rotors).
• Check brake fluid level and top off only if needed.
• Apply and release the parking brake to confirm normal operation (especially if EPB-equipped).
• Test drive at low speed first. Verify no grinding, pulling, or warning messages.
• Pad break-in: do 6–8 moderate stops from ~30 mph to 5 mph, allowing short cool-down between stops.

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💰 DIY vs Shop Cost

Shop Cost: $250-$450 (parts + labor)

DIY Cost: $60-$150 (parts only)

You Save: $190-$300 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-2.5 hours.

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🎯 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.