🔧 Fusion - Rear Brake Pad Replacement

You’ll remove the rear wheels, take the rear calipers off, swap the old pads for new ones, and reassemble with the correct torque. On your Fusion, the key detail is whether you have an electronic parking brake (EPB), because the rear calipers may need to be put into “service/maintenance mode” before compressing the piston.

Difficulty Level: Intermediate | Estimated Time: 1.5-3.0 hours

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⚠️ Safety & Precautions

• ⚠️ Work on level ground and support the car with jack stands—never rely on the jack.
• ⚠️ If equipped with electronic parking brake (EPB), do not force the piston in without EPB service mode—you can damage the caliper.
• ⚠️ Keep the key fob away and ignition OFF while working so the EPB can’t self-activate.
• ⚠️ Brake dust is harmful—use brake cleaner, not compressed air.
• ⚠️ Hybrid note: avoid touching any orange high-voltage cables/components (not part of this job).

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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)
• 13mm socket
• 15mm wrench
• 18mm socket
• Flat-blade screwdriver
• C-clamp brake piston compressor
• Brake caliper hanger hook
• 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/abutment clips - Qty: 1
• Brake lubricant (silicone/ceramic brake grease) - Qty: 1
• Brake cleaner - Qty: 1

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📋 Before You Begin

• 🧰 Park on level ground, set the parking brake, and place wheel chocks at the front wheels.
• 🧰 Open the hood and loosen (don’t remove) the brake fluid reservoir cap so fluid can move when pistons retract.
• 🧰 Identify your parking brake type:
  • EPB switch/button (electronic) = you should use EPB service/maintenance mode.
  • Foot pedal parking brake (mechanical) = no EPB service mode needed.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Put the parking brake system in the correct mode

• If you have an EPB switch: use a scan tool with Ford EPB service mode (specialty) to command EPB Maintenance/Service Mode.
• If you have a foot pedal parking brake: release the parking brake normally and continue.
• If unsure, look for an EPB button by the shifter.

Step 2: Lift the rear and remove the rear wheels

• Break the rear lug nuts loose using a 21mm socket and breaker bar (do not remove yet).
• Lift the rear using a floor jack at the proper rear jacking point, then support with jack stands.
• Remove the lug nuts with a 21mm socket and ratchet and take off both rear wheels.

Step 3: Remove the rear caliper (do one side at a time)

• Turn the steering wheel straight and look behind the rear caliper to find the two slide-pin bolts.
• Use a 13mm socket to remove the caliper slide bolts while holding the slide pin flat with a 15mm wrench.
• Lift the caliper off the bracket and hang it using a brake caliper hanger hook. Do not let it hang by the hose.

Step 4: Remove the old pads and hardware

• Pull the old inner and outer pads out by hand. Use a flat-blade screwdriver if they’re stuck.
• Remove the pad abutment clips (hardware) from the bracket.
• Clean the pad “landing” surfaces on the bracket with a wire brush and brake cleaner spray.

Step 5: Remove the caliper bracket (if required for pad/hardware access)

• If your new hardware won’t fit easily with the bracket in place, remove the bracket bolts using an 18mm socket and breaker bar.
• After reinstalling, Torque to 85 Nm (63 ft-lbs) using a torque wrench.

Step 6: Compress the rear caliper piston

• Check brake fluid level first—if it’s near MAX, remove a little fluid (do not overflow) before compressing.
• Use a C-clamp brake piston compressor to slowly press the piston straight back into the caliper.
• Go slowly and watch the reservoir while compressing.

Step 7: Install new hardware and new pads

• Install the new abutment clips onto the bracket.
• Apply a thin layer of brake lubricant where the pad ears contact the clips, and on the caliper slide-pin contact points. Do not get lube on pad friction material or rotor.
• Install the new inner and outer pads in the bracket.
• Pad ears should slide freely in clips.

Step 8: Reinstall the caliper and torque fasteners

• Place the caliper back over the new pads.
• Install the slide bolts using a 13mm socket while holding the slide with a 15mm wrench.
• Torque to 35 Nm (26 ft-lbs) using a torque wrench.

Step 9: Reinstall wheels and lower the car

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

Step 10: Exit EPB service mode (EPB-equipped only)

• Use the scan tool with Ford EPB service mode (specialty) to command EPB Normal Mode.

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✅ After Repair

• 🧪 Before starting the car, pump the brake pedal 10–15 times until it feels firm.
• 🧪 Check brake fluid level and reinstall the reservoir cap.
• 🧪 Apply and release the parking brake to confirm proper operation.
• 🧪 Test drive at low speed first; confirm no pulling, grinding, or warning lights.
• 🧪 Pad bed-in: make 6–10 moderate stops from 30–35 mph with cool-down between stops.

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💰 DIY vs Shop Cost

Shop Cost: $300-$550 (parts + labor)

DIY Cost: $60-$180 (parts only)

You Save: $240-$370 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.