🔧 Fusion - Suspension Bushing Replacement

Suspension bushings are rubber isolators pressed into control arms and links. On your Fusion, replacing them usually means removing the affected suspension arm and either pressing the bushing out/in or replacing the complete arm assembly.

Assumption: This guide covers the most common DIY-friendly job: front lower control arm bushing/control arm replacement. Pressing individual bushings requires a hydraulic press and is not beginner-friendly.

Difficulty Level: Advanced | Estimated Time: 3-5 hours

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⚠️ Safety & Precautions

• ⚠️ Support your Fusion with jack stands before working underneath. Never rely on a floor jack alone.
• ⚠️ Suspension bolts can be very tight. Use steady force and keep your body clear if a tool slips.
• ⚠️ Do not loosen strut, spring, or coil spring hardware. The spring is under heavy tension.
• ⚠️ Final tightening of control arm bushing bolts must be done at normal ride height to prevent bushing twist and early failure.
• ⚠️ A wheel alignment is required after this repair.
• ⚠️ Battery disconnect is not required for this repair.

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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
• 1/2-inch drive breaker bar
• 1/2-inch drive torque wrench
• 3/8-inch drive ratchet
• 18mm socket
• 21mm socket
• 22mm socket
• 18mm wrench
• 21mm wrench
• 22mm wrench
• Pry bar set
• Ball joint separator (specialty)
• Hammer, 2-lb
• Paint marker
• Penetrating oil
• Mechanic gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front lower control arm assembly with bushings and ball joint - Qty: 1 per side
• Front lower control arm mounting bolts - Qty: 2 per side
• Front lower ball joint pinch bolt and nut - Qty: 1 per side
• Front stabilizer link nut - Qty: 1 per side if removed

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📋 Before You Begin

• Park your Fusion on level ground and set the parking brake.
• Place wheel chocks behind the rear wheels.
• Loosen the front wheel lug nuts slightly before lifting the vehicle.
• Spray penetrating oil on the control arm bolts and ball joint pinch bolt at least 10 minutes before removal.
• A ball joint separator is a tool that separates the tapered ball joint stud from the steering knuckle without damaging nearby parts.
• A torque wrench is a tool that tightens bolts to a specific force 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 Wheel

• Use the 21mm socket and 1/2-inch drive breaker bar to loosen the lug nuts on the side you are repairing.
• Only loosen them about half a turn while the tire is still on the ground.
• Tip: Do one side at a time.

Step 2: Raise and Support the Vehicle

• Use the floor jack to lift the front of your Fusion at the proper front jacking point.
• Place jack stands under the front support points.
• Lower the vehicle gently onto the jack stands.
• Use the floor jack lightly under the subframe as backup support.

Step 3: Remove the Wheel

• Use the 21mm socket and 3/8-inch drive ratchet to remove the loosened lug nuts.
• Remove the wheel and set it flat under the vehicle as an extra safety backup.

Step 4: Mark the Control Arm Position

• Use the paint marker to mark the current position of the control arm mounting points.
• This does not replace an alignment, but it helps keep the vehicle close enough to drive carefully to the alignment shop.

Step 5: Remove the Ball Joint Pinch Bolt

• Locate the lower ball joint where the control arm connects to the steering knuckle.
• Use the 18mm socket and 18mm wrench to remove the ball joint pinch bolt and nut.
• If the bolt is stuck, apply penetrating oil and gently tap the bolt with the 2-lb hammer.
• Do not strike the rubber boot directly.

Step 6: Separate the Ball Joint from the Knuckle

• Use the ball joint separator to carefully separate the ball joint stud from the steering knuckle.
• Use the pry bar set to gently move the control arm downward if needed.
• Be careful not to pull on the brake hose or wheel speed sensor wiring.

Step 7: Remove the Control Arm Mounting Bolts

• Use the 21mm socket, 22mm socket, 21mm wrench, and 22mm wrench as needed to remove the front and rear control arm mounting bolts.
• Support the arm with one hand while removing the last bolt.
• Remove the control arm from the vehicle.
• Tip: Compare old and new parts first.

Step 8: Install the New Control Arm

• Position the new front lower control arm assembly into the subframe.
• Install the new mounting bolts by hand first to avoid cross-threading.
• Use the 21mm socket, 22mm socket, 21mm wrench, and 22mm wrench to snug the bolts only.
• Do not fully tighten the bushing bolts yet.

Step 9: Reconnect the Ball Joint

• Guide the ball joint stud into the steering knuckle by hand.
• Use the pry bar set carefully if the arm needs slight movement.
• Install the new pinch bolt and nut.
• Use the 18mm socket, 18mm wrench, and 1/2-inch drive torque wrench to tighten the ball joint pinch bolt to Torque to 63 Nm (46 ft-lbs).

Step 10: Load the Suspension Before Final Tightening

• Use the floor jack under the outer control arm area to raise the suspension until it is near normal ride height.
• Normal ride height means the control arm sits about where it does when the vehicle is resting on its wheels.
• This prevents the new rubber bushings from being twisted at rest.

Step 11: Tighten the Control Arm Mounting Bolts

• Use the 21mm socket, 22mm socket, 21mm wrench, 22mm wrench, and 1/2-inch drive torque wrench to tighten the front control arm mounting bolt to Torque to 175 Nm (129 ft-lbs).
• Use the same tools to tighten the rear control arm mounting bolt to Torque to 175 Nm (129 ft-lbs).
• If your replacement hardware includes torque-angle instructions, follow the hardware instructions supplied with the parts.

Step 12: Reinstall the Wheel

• Use the 21mm socket and 3/8-inch drive ratchet to install the lug nuts by hand.
• Snug the lug nuts in a star pattern.
• Use the floor jack to lift slightly, remove the jack stands, and lower your Fusion to the ground.
• Use the 21mm socket and 1/2-inch drive torque wrench to tighten the lug nuts to Torque to 204 Nm (150 ft-lbs).

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✅ After Repair

• Turn the steering wheel lock-to-lock while parked and listen for clunks or binding.
• Take a slow test drive on a smooth road first.
• Listen for knocking, popping, or rubbing noises.
• Recheck the lug nut torque after the test drive using the 21mm socket and 1/2-inch drive torque wrench.
• Schedule a four-wheel alignment as soon as possible. Do not skip this.
• If the steering wheel is off-center or the vehicle pulls, drive only carefully to the alignment shop.

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💰 DIY vs Shop Cost

Shop Cost: $450-$850 per side (parts + labor)

DIY Cost: $120-$300 per side (parts only)

You Save: $330-$550 per side by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-3 hours per side.

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🎯 Ready to get started?

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