🔧 Fusion - Front Brake Pads & Rotors Replacement

This repair replaces the front brake pads and front brake rotors on your Fusion. Worn pads or warped rotors can cause squealing, grinding, vibration, longer stopping distance, or brake pedal pulsation.

Difficulty Level: Beginner/Intermediate | Estimated Time: 2-3 hours

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⚠️ Safety & Precautions

• ⚠️ Work on level ground only. Never rely on a jack by itself; always support your Fusion with jack stands.
• ⚠️ Brake dust can be harmful. Wear safety glasses and a dust mask, and do not blow brake dust with compressed air.
• ⚠️ The front brakes do not require electronic parking brake service mode on your Fusion. The parking brake acts on the rear brakes.
• ⚠️ If brake fluid overflows while compressing the caliper piston, wipe it immediately because it damages paint.
• ⚠️ Replace front brake pads as a complete axle set. Do both front sides together.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 2-ton minimum)
• Jack stands (rated 2-ton minimum)
• Wheel chocks
• 19mm lug nut socket
• Breaker bar 1/2-inch drive
• Torque wrench 1/2-inch drive
• Ratchet 3/8-inch drive
• 7mm hex bit socket
• 18mm socket
• Flathead screwdriver
• C-clamp or disc brake caliper piston compressor (specialty)
• Brake caliper hanger hook
• Wire brush
• Brake parts cleaning brush
• Rubber mallet
• Brake cleaner spray nozzle
• Shop towels
• Brake fluid catch pan
• Nitrile gloves
• Safety glasses
• Dust mask

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🔩 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 kit - Qty: 1
• Brake cleaner - Qty: 1-2 cans
• Synthetic brake lubricant - Qty: 1 packet/tube
• High-temperature anti-seize compound - Qty: 1 small packet
• DOT 4 brake fluid - Qty: 1 small bottle if topping off is needed

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📋 Before You Begin

• 🚗 Park your Fusion on a flat, solid surface.
• 🅿️ Shift to Park and apply the parking brake before lifting the vehicle.
• 🧱 Place wheel chocks behind the rear wheels. Wheel chocks are wedge blocks that stop the vehicle from rolling.
• 🧤 Put on safety glasses, gloves, and a dust mask before working around the brakes.
• 💧 Open the hood and check the brake fluid reservoir. If it is at the MAX line, remove a small amount with a clean suction tool before compressing the caliper pistons.
• 📌 Brake lubricant is grease made for brakes. Use it only on pad contact points and slide pins, never on the pad friction surface or rotor face.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the Front Lug Nuts

• Use a 19mm lug nut socket and 1/2-inch breaker bar to loosen each front wheel lug nut about 1/2 turn.
• Do this while the tires are still touching the ground so the wheels do not spin.
• Do not remove the lug nuts yet.

Step 2: Lift and Support the Front of the Vehicle

• Use a floor jack at the correct front jacking point to raise the front of your Fusion.
• Place jack stands under the proper front support points.
• Slowly lower the vehicle onto the jack stands.
• Gently shake the vehicle by hand to confirm it is stable before removing the wheels.

Step 3: Remove the Front Wheels

• Use the 19mm lug nut socket to remove the loosened lug nuts.
• Remove both front wheels and place them flat under the side of the vehicle as an extra safety backup.

Step 4: Remove the Caliper Spring Clip

• Use a flathead screwdriver to carefully pry the metal spring clip off the outside of the front brake caliper.
• Hold the clip with your other hand so it does not fly away.
• A caliper is the clamp-shaped brake part that squeezes the pads against the rotor.

Step 5: Remove the Caliper Slide Pin Bolts

• Remove the rubber caps from the back of the caliper slide pins by hand.
• Use a 7mm hex bit socket and 3/8-inch ratchet to remove the two caliper slide pin bolts.
• Slide pins are smooth guide bolts that let the caliper move evenly as the pads wear.

Step 6: Remove and Support the Caliper

• Use a flathead screwdriver to gently work the caliper loose if it is stuck.
• Lift the caliper off the rotor.
• Hang the caliper from the suspension using a brake caliper hanger hook.
• Do not let the caliper hang by the rubber brake hose.

Step 7: Remove the Old Brake Pads

• Pull the outer brake pad out of the caliper bracket by hand.
• Pull the inner brake pad out of the caliper piston by hand.
• Use a flathead screwdriver only if a pad is stuck, and pry gently.
• The piston is the round part inside the caliper that pushes the pad into the rotor.

Step 8: Compress the Caliper Piston

• Place an old brake pad against the caliper piston.
• Use a C-clamp or disc brake caliper piston compressor to slowly push the piston fully back into the caliper.
• Watch the brake fluid reservoir under the hood while compressing the piston.
• If fluid rises too high, use a brake fluid catch pan and shop towels to control any spill.
• Go slowly to protect the brake system.

Step 9: Remove the Caliper Bracket

• Use an 18mm socket and 1/2-inch breaker bar to remove the two caliper bracket bolts.
• Remove the caliper bracket from the steering knuckle.
• The caliper bracket is the metal frame that holds the pads in place.

Step 10: Remove the Old Rotor

• Pull the rotor straight off the wheel hub by hand.
• If the rotor is stuck from rust, tap around the rotor hat with a rubber mallet.
• Do not strike the wheel studs.
• The rotor hat is the raised center section of the brake rotor.

Step 11: Clean the Hub Surface

• Use a wire brush to clean rust from the wheel hub face.
• Wipe the hub with brake cleaner and shop towels.
• Apply a very thin film of high-temperature anti-seize compound to the hub face with a gloved finger.
• Keep anti-seize off the wheel studs and rotor braking surface.
• A clean hub helps prevent brake vibration.

Step 12: Install the New Rotor

• Clean both sides of the new rotor using brake cleaner and shop towels.
• Slide the new rotor onto the hub by hand.
• Thread one lug nut on by hand to hold the rotor flat while you work.

Step 13: Clean and Prepare the Caliper Bracket

• Use a flathead screwdriver to remove the old pad hardware clips from the caliper bracket.
• Use a wire brush and brake parts cleaning brush to clean the bracket where the clips sit.
• Spray the bracket with brake cleaner and dry it with shop towels.
• Install the new hardware clips by hand.
• Apply a thin layer of synthetic brake lubricant to the pad contact points on the hardware clips.
• Do not put lubricant on the rotor or pad friction material.

Step 14: Reinstall the Caliper Bracket

• Position the caliper bracket over the new rotor.
• Start both bracket bolts by hand to avoid cross-threading.
• Use an 18mm socket and torque wrench to tighten the caliper bracket bolts.
• Torque to 175 Nm (129 ft-lbs)

Step 15: Lubricate the Slide Pins

• Pull each slide pin out of the caliper by hand.
• Wipe the pins with shop towels.
• Apply a light coat of synthetic brake lubricant to each slide pin.
• Reinsert the pins by hand and make sure they move smoothly.
• Sticky slide pins cause uneven pad wear.

Step 16: Install the New Brake Pads

• Install the new inner and outer brake pads into the caliper bracket by hand.
• Make sure the pad friction material faces the rotor.
• If the pads include wear indicators, install them in the same general position as the old pads.
• Use only a tiny amount of synthetic brake lubricant on pad ears where they touch the hardware clips.

Step 17: Reinstall the Caliper

• Remove the caliper from the brake caliper hanger hook.
• Slide the caliper over the new pads and rotor by hand.
• Start both slide pin bolts by hand.
• Use a 7mm hex bit socket and torque wrench to tighten the slide pin bolts.
• Torque to 35 Nm (26 ft-lbs)
• Reinstall the rubber slide pin caps by hand.

Step 18: Reinstall the Caliper Spring Clip

• Use your hands and a flathead screwdriver to reinstall the spring clip on the outside of the caliper.
• Make sure the clip is fully seated and centered.

Step 19: Repeat on the Other Front Side

• Repeat Steps 4 through 18 on the other front wheel.
• Use the same tools and torque specs on both sides.

Step 20: Reinstall the Front Wheels

• Remove the temporary lug nut holding each rotor in place by hand.
• Install each front wheel onto the hub.
• Thread all lug nuts by hand first.
• Use a 19mm lug nut socket and ratchet to snug the lug nuts in a star pattern.

Step 21: Lower the Vehicle and Torque the Lug Nuts

• Use the floor jack to lift the vehicle slightly off the jack stands.
• Remove the jack stands.
• Lower the vehicle until the tires touch the ground.
• Use a 19mm lug nut socket and torque wrench to tighten the lug nuts in a star pattern.
• Torque to 135 Nm (100 ft-lbs)

Step 22: Pump the Brake Pedal

• Sit in the driver seat and press the brake pedal slowly several times.
• Keep pumping until the pedal feels firm.
• This moves the caliper pistons back against the new pads.
• Do not drive before the pedal feels firm.

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✅ After Repair

• ✅ Check the brake fluid level and top off with DOT 4 brake fluid only if needed.
• ✅ Start your Fusion and press the brake pedal again. It should feel firm, not sink to the floor.
• ✅ Check around both front calipers for leaks or twisted brake hoses.
• ✅ Test drive slowly in a safe area before normal driving.
• ✅ Bed in the new pads if the pad manufacturer recommends it. A common method is 8-10 moderate stops from about 35 mph to 10 mph, allowing cooling time between stops.
• ✅ Avoid hard braking for the first 200 miles unless it is an emergency.
• ✅ Recheck lug nut torque after 25-50 miles using the 19mm lug nut socket and torque wrench.

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💰 DIY vs Shop Cost

Shop Cost: $350-$650 (parts + labor)

DIY Cost: $120-$260 (parts only)

You Save: $230-$390 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-2.0 hours.

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