🔧 Fusion - Front Brake Pad Replacement

This repair replaces the front brake pads on your Fusion. The front pads press against the brake rotors to slow the car, and worn pads can cause noise, longer stopping distance, or rotor damage.

Difficulty Level: Beginner | Estimated Time: 1.5-2.5 hours

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⚠️ Safety & Precautions

• ⚠️ Your Fusion is a plug-in hybrid, so do not touch any orange high-voltage cables or high-voltage components.
• ⚠️ Work on a cool brake system only. Brake parts can stay hot after driving.
• ⚠️ Use jack stands every time. Never rely on a floor jack alone.
• ⚠️ The brake caliper is the metal clamp over the rotor. Do not let it hang by the rubber brake hose.
• ⚠️ Brake dust is harmful. Do not blow it with compressed air; use brake cleaner instead.
• ⚠️ Do not disconnect the 12V battery for this brake pad job unless you are performing additional electrical work.

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🔧 Required Tools

You'll need the following tools for this repair:

• 19mm lug nut socket
• Ratchet wrench, 3/8-inch drive
• 7mm hex socket
• Torque wrench, 10-150 ft-lb range
• Flat blade screwdriver, medium
• Brake caliper piston compressor tool (specialty)
• Brake caliper hanger hook (specialty)
• Floor jack, rated 2-ton minimum
• Jack stands, rated 2-ton minimum
• Wheel chocks
• Wire brush, small
• Brake cleaner spray nozzle
• Catch pan
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front brake pad set - Qty: 1
• Front brake pad hardware kit - Qty: 1
• Brake cleaner - Qty: 1 can
• High-temperature brake lubricant - Qty: 1 tube

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📋 Before You Begin

• Park your Fusion on level ground and shift to Park.
• Set the parking brake before lifting the vehicle.
• Place wheel chocks behind the rear tires. Wheel chocks are wedges that stop the car from rolling.
• Open the hood and check the brake fluid reservoir level. If it is at the MAX line, remove a small amount with a clean suction tool before pushing the caliper pistons back.
• Front brake pads on your Fusion do not require infotainment menu steps, electronic parking brake service mode, or scan-tool retraction.

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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 ratchet wrench to loosen each front wheel lug nut about one turn.
• Do this while the tire is still on the ground so the wheel does not spin.
• Loosen first, lift second.

Step 2: Lift and Support the Front of the Car

• Use a floor jack, rated 2-ton minimum at the proper front jacking point to raise the front of your Fusion.
• Place jack stands, rated 2-ton minimum under the approved front support points.
• Gently lower the vehicle onto the jack stands and lightly shake the car to confirm it is stable.
• Keep the floor jack nearby as a backup, but do not use it as the only support.

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 car as an extra safety backup.

Step 4: Inspect the Brake Assembly

• Put on safety glasses and nitrile gloves.
• Use the brake cleaner spray nozzle and catch pan to clean dust from the caliper and rotor area.
• Look at the rotor surface. If it has deep grooves, heavy rust, blue heat spots, or vibration while braking, the rotors should be serviced or replaced with the pads.

Step 5: Remove the Caliper Guide Pin Bolts

• Locate the two caliper guide pin bolts on the back side of the front brake caliper.
• Use a 7mm hex socket and ratchet wrench to remove the upper and lower guide pin bolts.
• A guide pin lets the caliper slide evenly as the pads wear.

Step 6: Lift the Caliper Off the Bracket

• Use a flat blade screwdriver, medium to gently pry the caliper outward just enough to loosen it.
• Slide the caliper off the rotor by hand.
• Use a brake caliper hanger hook to hang the caliper from the front suspension spring or strut area.
• Do not pull, kink, or stretch the brake hose.

Step 7: Remove the Old Brake Pads and Hardware

• Pull the inner and outer brake pads out of the caliper bracket by hand.
• Use a flat blade screwdriver, medium if a pad is stuck, but do not gouge the bracket.
• Remove the old pad clips from the caliper bracket by hand or with the flat blade screwdriver, medium.

Step 8: Clean the Caliper Bracket

• Use a wire brush, small to clean rust and dirt where the brake pad hardware sits.
• Use the brake cleaner spray nozzle and catch pan to rinse the cleaned areas.
• Let the parts dry before applying lubricant.
• Clean brackets prevent pad sticking.

Step 9: Compress the Caliper Piston

• Place an old brake pad against the caliper piston.
• Use the brake caliper piston compressor tool to slowly push the piston fully back into the caliper.
• Watch the brake fluid reservoir while compressing the piston. Stop if fluid rises too high.
• The piston is the round part that pushes the inner brake pad during braking.

Step 10: Install New Brake Pad Hardware

• Snap the new front brake pad hardware kit clips into the caliper bracket by hand.
• Use a small amount of high-temperature brake lubricant on the contact points where the pad ears slide in the hardware.
• Do not put lubricant on the rotor face or pad friction material.

Step 11: Install the New Brake Pads

• Slide the new front brake pad set into the caliper bracket by hand.
• Make sure the pads move freely in the clips without binding.
• If the pads are tight, remove them and use the wire brush, small to clean the bracket again.

Step 12: Reinstall the Caliper

• Remove the caliper from the brake caliper hanger hook.
• Slide the caliper over the new pads by hand.
• Install the guide pin bolts by hand first to prevent cross-threading.
• Use the 7mm hex socket and torque wrench, 10-150 ft-lb range to tighten the front caliper guide pin bolts to Torque to 35 Nm (26 ft-lbs).

Step 13: Repeat on the Other Front Side

• Use the same tools and repeat Steps 4 through 12 on the other front brake assembly.
• Always replace front brake pads in pairs so braking stays even.

Step 14: Reinstall the Front Wheels

• Place each wheel back onto the hub by hand.
• Start all lug nuts by hand to avoid cross-threading.
• Use the 19mm lug nut socket to snug the lug nuts in a star pattern.

Step 15: Lower the Vehicle and Torque the Lug Nuts

• Use the floor jack, rated 2-ton minimum to raise the car slightly off the jack stands.
• Remove the jack stands, rated 2-ton minimum.
• Lower the vehicle fully to the ground.
• Use the 19mm lug nut socket and torque wrench, 10-150 ft-lb range to tighten the lug nuts in a star pattern to Torque to 135 Nm (100 ft-lbs).

Step 16: Pump the Brake Pedal

• Before moving the vehicle, press the brake pedal slowly several times until it feels firm.
• This moves the caliper pistons back against the new pads.
• If the pedal does not become firm, do not drive the car.

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✅ After Repair

• Check the brake fluid level and make sure it is between MIN and MAX.
• Start your Fusion and confirm the brake pedal feels firm before shifting out of Park.
• Test the brakes at very low speed in a safe area before normal driving.
• Bed in the new pads if the pad maker requires it. A common method is several moderate stops from 30-40 mph with cooling time between stops.
• Avoid hard braking for the first 100-200 miles unless needed for safety.
• After the first short drive, recheck for unusual noise, burning smell, or fluid leaks.

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💰 DIY vs Shop Cost

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

DIY Cost: $45-$120 (parts only)

You Save: $130-$330 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.0-1.5 hours.

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