🔧 Fusion - Front Brake Pad Replacement

This repair replaces the front brake pads on your Fusion. The front pads wear down over time and should be replaced before they damage the brake rotors or reduce stopping power.

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

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⚠️ Safety & Precautions

• ⚠️ Work on a flat, solid surface only. Never rely on a jack by itself.
• 🧤 Wear safety glasses and gloves. Brake dust is irritating and should not be blown with compressed air.
• 🔥 Let the brakes cool completely before starting.
• 🛑 Use wheel chocks behind the rear wheels so the car cannot roll.
• 🔋 Battery disconnect is not required for front brake pad replacement on your Fusion.
• ⚙️ The electronic parking brake only affects the rear brakes, not the front pads for this repair.

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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
• Ratchet wrench 3/8-inch drive
• Torque wrench 1/2-inch drive
• 7mm hex socket
• Flathead screwdriver
• C-clamp 6-inch
• Brake caliper piston compression tool (specialty)
• Brake parts cleaning brush
• Catch pan
• Turkey baster or fluid syringe
• Safety glasses
• Nitrile gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front brake pad set - Qty: 1
• Front brake hardware kit - Qty: 1
• Brake lubricant - Qty: 1
• Brake cleaner spray - Qty: 1
• DOT 4 brake fluid - Qty: 1 pint

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📋 Before You Begin

• 🚗 Park your Fusion on level ground and shift to Park.
• 🛑 Apply the parking brake before lifting the front of the car.
• 🧱 Place wheel chocks behind both rear wheels.
• 🧴 Open the hood and check the brake fluid level. If it is near MAX, use a turkey baster or fluid syringe to remove a small amount into a catch pan.
• 📌 A brake caliper is the clamp-like part that squeezes the brake pads against the rotor to stop the car.
• 📌 A torque wrench tightens bolts to the correct tightness so they are not too loose or too tight.

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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 3/8-inch drive 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.
• Loosen only, do not remove yet.

Step 2: Lift and Support the Front of the Car

• Use a floor jack rated 2-ton minimum at the front jacking point to raise the front of your Fusion.
• Place jack stands rated 2-ton minimum under the proper front support points.
• Slowly lower the car onto the jack stands.
• Gently shake the car by hand to confirm it is stable before working near 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 set them flat on the ground.
• Slide one wheel under the side of the car as an extra safety backup.

Step 4: Turn the Steering for Better Access

• Turn the steering wheel to point the brake caliper outward on the side you are working on.
• Use your hands only. No tool is needed for this step.
• This gives you more room to reach the caliper bolts.

Step 5: Remove the Caliper Spring Clip

• Use a flathead screwdriver to carefully pry the outer caliper spring clip away from the caliper.
• Hold the clip with one hand so it does not fly off.
• Set it aside for reuse if your new hardware kit does not include one.

Step 6: Remove the Caliper Guide Pin Bolts

• Locate the two rubber caps on the back of the front caliper.
• Use your fingers or a flathead screwdriver to remove the rubber caps.
• Use a 7mm hex socket and ratchet wrench 3/8-inch drive to remove the two caliper guide pin bolts.
• A guide pin is a smooth bolt that lets the caliper slide evenly as the pads wear.

Step 7: Lift Off the Brake Caliper

• Use your hands to slide the caliper off the brake pads and rotor.
• If it is tight, gently use a flathead screwdriver between the old pad and rotor to create a little space.
• Do not let the caliper hang by the rubber brake hose.
• Rest the caliper securely on the suspension or support it with care.

Step 8: Remove the Old Brake Pads

• Use your hands to pull the outer brake pad out of the caliper bracket.
• Use your hands to remove the inner brake pad from the caliper piston area.
• Note how the pads and clips are installed before removing everything.
• Take a phone photo before disassembly.

Step 9: Inspect the Rotor and Hardware

• Use a brake parts cleaning brush to clean loose rust and dust from the pad contact areas.
• Use brake cleaner spray and a catch pan to rinse brake dust away.
• If the rotor has deep grooves, heavy rust, blue heat spots, or vibration while braking, replace or resurface the rotors before installing new pads.

Step 10: Compress the Caliper Piston

• Place one old brake pad against the caliper piston.
• Use a 6-inch C-clamp or brake caliper piston compression tool to slowly press the piston fully back into the caliper.
• Watch the brake fluid reservoir under the hood while compressing the piston.
• If the fluid rises close to MAX, use a turkey baster or fluid syringe to remove a small amount into a catch pan.
• Do not spill brake fluid on paint because it can damage the finish.

Step 11: Install New Brake Hardware

• Use your hands to install the new front brake hardware clips into the caliper bracket.
• Apply a thin layer of brake lubricant to the metal pad contact points on the clips.
• Do not put lubricant on the brake pad friction material or rotor face.
• A tiny amount is enough.

Step 12: Install the New Brake Pads

• Use your hands to slide the new inner and outer front brake pads into position.
• Make sure the friction material faces the rotor.
• The pads should move smoothly in the clips without being loose.

Step 13: Reinstall the Caliper

• Use your hands to place the caliper back over the new pads and rotor.
• Use the 7mm hex socket and ratchet wrench 3/8-inch drive to start both guide pin bolts by hand first.
• Use the torque wrench 1/2-inch drive with the 7mm hex socket to tighten the caliper guide pin bolts to Torque to 28 Nm (21 ft-lbs).
• Reinstall the rubber guide pin caps by hand.

Step 14: Reinstall the Caliper Spring Clip

• Use your hands and a flathead screwdriver to reinstall the outer caliper spring clip.
• Make sure both ends of the clip are fully seated in the caliper holes.
• The clip should sit flat and tight against the caliper.

Step 15: Repeat on the Other Front Side

• Repeat Steps 4 through 14 on the other front brake assembly.
• Use the same 7mm hex socket, flathead screwdriver, brake parts cleaning brush, and brake caliper piston compression tool.
• Always replace front brake pads as a complete axle set, meaning both front sides together.

Step 16: Reinstall the Front Wheels

• Lift each wheel onto the hub by hand.
• Use the 19mm lug nut socket to install the lug nuts finger-tight first.
• Snug the lug nuts lightly in a star pattern with the ratchet wrench 3/8-inch drive.

Step 17: Lower the Car and Torque the Lug Nuts

• Use the floor jack rated 2-ton minimum to lift the car slightly off the jack stands.
• Remove the jack stands rated 2-ton minimum.
• Lower the car until the tires touch the ground.
• Use the torque wrench 1/2-inch drive and 19mm lug nut socket to tighten the lug nuts in a star pattern to Torque to 135 Nm (100 ft-lbs).

Step 18: Pump the Brake Pedal

• Sit in the driver seat and press the brake pedal slowly several times until it feels firm.
• This moves the caliper pistons back out against the new pads.
• Do not drive until 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.
• 🧽 Clean any spilled brake fluid immediately with water.
• 🛞 Recheck lug nut torque after the first short drive using the torque wrench 1/2-inch drive.
• 🚦 Test the brakes at low speed in a safe area before normal driving.
• 🧱 Bed in the new pads with 8-10 moderate stops from about 30 mph to 5 mph, allowing time between stops for cooling.
• 🔥 Avoid hard braking for the first 100-200 miles unless needed for safety.

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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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🎯 Ready to get started?

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