🔧 Fusion - Wheel Bearing Replacement

On your Fusion, the wheel bearing is part of a sealed hub-and-bearing assembly. Replacement is a remove-and-replace job (no bearing press), but rust and tight fasteners can make it challenging.

Difficulty Level: Advanced | Estimated Time: 2.5-5.0 hours (one corner)

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⚠️ Safety & Precautions

• 🛑 Support the car with jack stands on solid points; never rely on a floor jack alone.
• 🧤 Wear safety glasses and mechanic gloves; rust scale can fall when the hub breaks loose.
• 🔥 Brakes get hot—let everything cool before touching the rotor/caliper.
• ⚡ Hybrid note: keep the car OFF and keep the key fob away from the car so it can’t wake up unexpectedly.
• 🧷 Do not let the brake caliper hang by the hose—support it with a hanger.

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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
• Safety glasses
• Mechanic gloves
• Breaker bar (1/2" drive)
• Torque wrench (20–250 ft-lbs range)
• Socket set (8mm–21mm, 1/2" drive)
• Wrench set (8mm–21mm)
• Axle nut socket (32mm, 1/2" drive)
• Ratchet (3/8" drive)
• Torx bit set (T30–T50)
• Pry bar (18")
• Hammer (2–3 lb)
• Wire brush
• Bungee cord
• Penetrating oil
• Hub puller/slide hammer kit (specialty)

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front wheel hub & bearing assembly - Qty: 1
• Rear wheel hub & bearing assembly - Qty: 1
• Front axle nut (one-time-use) - Qty: 1
• Brake caliper bracket bolts - Qty: 2 (optional if specified one-time-use)
• Brake rotor retaining screw - Qty: 1 (optional if equipped)
• Brake cleaner - Qty: 1
• Anti-seize compound - Qty: 1

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📋 Before You Begin

• Park on level ground. Turn the car OFF. Keep the key fob at least 15 feet away.
• Chock the wheels that will stay on the ground with wheel chocks.
• Loosen the wheel lug nuts slightly using a 19mm socket and breaker bar before lifting.
• If doing a rear hub: make sure the parking brake is released. If your Fusion has an electronic parking brake that won’t release, you may need a scan tool parking-brake service mode.
• Tip: Spray penetrating oil on hub bolts 10 minutes early.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and remove the wheel

• Use a floor jack to lift the corner you’re working on.
• Set the car down onto jack stands.
• Remove the lug nuts with a 19mm socket and remove the wheel.

Step 2 (Front): Remove the axle nut

• Remove any axle-nut cap (if present) using a small pry bar.
• Use a 32mm axle nut socket and breaker bar to remove the axle nut.
• Tip: Have a helper press the brake pedal.

Step 3: Remove the brake caliper and bracket

• Remove the caliper slide bolts using the correct socket/wrench (commonly 13mm).
• Lift the caliper off and hang it from the strut/spring with a bungee cord.
• Remove the caliper bracket bolts using a breaker bar and appropriate socket (commonly 15mm–18mm).
• Torque to 115 Nm (85 ft-lbs) when reinstalling (caliper bracket bolts).

Step 4: Remove the brake rotor

• If equipped with a rotor retaining screw, remove it with a Torx bit (commonly T30).
• Pull the rotor off. If stuck, tap the rotor hat with a hammer (avoid the wheel studs).

Step 5: Disconnect the wheel speed sensor (ABS) wiring

• Unclip the ABS wire from its holders using a trim tool or careful hand pressure.
• Disconnect the connector if needed (do not pull on the wire).
• Definition: The ABS sensor reads wheel speed for braking and stability control.

Step 6 (Front): Push the axle stub back slightly

• Thread the old axle nut on a few turns by hand to protect the threads.
• Use a hammer to tap the nut and push the axle inward slightly.
• Remove the nut again using the 32mm socket.
• Tip: If it won’t move, don’t mushroom the threads—use a puller.

Step 7: Remove the hub/bearing mounting bolts

• From the back side of the knuckle, remove the 3–4 hub bolts using a ratchet and appropriate socket (often 13mm–15mm).
• Use penetrating oil and a breaker bar if they’re stubborn.
• Torque to 90 Nm (66 ft-lbs) when reinstalling (hub-to-knuckle bolts).

Step 8: Remove the hub/bearing assembly

• Pull the hub straight out of the knuckle.
• If it’s rust-seized, use a hub puller/slide hammer kit (specialty) to pop it out.
• Clean the knuckle bore with a wire brush and wipe with brake cleaner.

Step 9: Install the new hub/bearing assembly

• Apply a very thin film of anti-seize compound to the knuckle bore (keep it off the brake surfaces).
• Set the new hub squarely in place by hand.
• Install hub bolts finger-tight, then tighten evenly using a ratchet.
• Torque to 90 Nm (66 ft-lbs) (hub-to-knuckle bolts).
• Reconnect and re-clip the ABS wiring by hand.

Step 10 (Front): Install a new axle nut

• Install the new axle nut by hand first to avoid cross-threading.
• Tighten using a torque wrench and 32mm socket: Torque to 300 Nm (221 ft-lbs).
• Tip: Axle nuts are often one-time-use—replace it.

Step 11: Reinstall rotor, bracket, and caliper

• Reinstall the rotor. If equipped, install the retaining screw with a Torx bit and snug it (do not over-tighten).
• Reinstall the caliper bracket using the correct socket.
• Torque to 115 Nm (85 ft-lbs) (caliper bracket bolts).
• Reinstall the caliper and tighten slide bolts using the correct socket/wrench.
• Torque to 35 Nm (26 ft-lbs) (caliper slide bolts).

Step 12: Reinstall wheel and lower the car

• Install the wheel and hand-tighten lug nuts.
• Lower the car using the floor jack.
• Tighten lug nuts in a star pattern with a torque wrench: Torque to 135 Nm (100 ft-lbs).

Assumption note: Torque values above are the common Fusion hub/brake specs; always match to your exact service info if any fastener/type differs.

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✅ After Repair

• Before moving, pump the brake pedal 5–10 times until it feels firm.
• Start the car and confirm no ABS/traction warning lights stay on.
• Road test at low speed first. Listen for grinding/humming and check for pulling.
• Recheck lug nut torque with a torque wrench after 25–50 miles.

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💰 DIY vs Shop Cost

Shop Cost: $450-$950 (parts + labor, per wheel)

DIY Cost: $120-$280 (parts only, per wheel)

You Save: $330-$670 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2.5-5.0 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.