🔧 Fusion - Front Strut Assembly Replacement

This repair replaces the front strut assemblies on your Fusion. The strut supports the vehicle, controls bouncing, and helps keep the tire firmly on the road.

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

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⚠️ Safety & Precautions

• ⚠️ The high-voltage hybrid battery does not need to be serviced for this front strut job, but do not touch orange high-voltage cables or connectors.
• ⚠️ Always support your Fusion with jack stands. Never work under a vehicle supported only by a floor jack.
• ⚠️ Front struts contain compressed spring force. Use complete pre-assembled strut assemblies if you are a beginner.
• ⚠️ If reusing the coil springs, a strut spring compressor is required. This tool compresses the spring, and misuse can cause serious injury.
• ⚠️ Disconnecting the 12V battery is not required for normal front strut replacement.
• ⚠️ An alignment is required after replacing front struts.

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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
• 1/2-inch drive breaker bar
• 1/2-inch drive torque wrench
• 3/8-inch drive ratchet
• 13mm socket
• 15mm socket
• 18mm socket
• 21mm socket
• 18mm wrench
• 21mm wrench
• 6mm Allen key socket
• Flat-blade screwdriver
• Trim clip removal tool
• Needle-nose pliers
• Paint marker
• Rubber mallet
• Pry bar 18-inch
• Penetrating oil
• Strut spring compressor (specialty)
• Safety glasses
• Mechanic gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front complete strut assembly - Left: 1, Right: 1
• Front strut-to-knuckle bolt and nut kit - Qty: 2 sets
• Front stabilizer bar link nut - Qty: 2
• Front upper strut mount nuts - Qty: 6
• Wheel alignment service - Qty: 1

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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 lug nuts slightly with a 19mm lug nut socket and 1/2-inch drive breaker bar before lifting the vehicle.
• 🧰 A torque wrench tightens fasteners to an exact force so parts do not loosen or get damaged.
• ✅ For a beginner, use complete strut assemblies. This avoids compressing the old coil spring.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and Support the Front

• Use the 19mm lug nut socket and 1/2-inch drive breaker bar to loosen each front lug nut about 1/2 turn.
• Use the floor jack at the front center jacking point or the side pinch weld lift points.
• Place jack stands under the approved front pinch weld support points.
• Lower the vehicle gently onto the jack stands and shake the vehicle lightly to confirm it is stable.
• Remove the front wheels using the 19mm lug nut socket.

Step 2: Mark the Strut Position

• Use a paint marker to draw alignment marks where the strut meets the steering knuckle.
• The steering knuckle is the large metal part that holds the wheel hub and connects to the strut.
• Marks help you get close before alignment.

Step 3: Remove Brake Hose and ABS Wire Brackets

• Use a 13mm socket or 15mm socket as fitted to remove the brake hose bracket bolt from the strut.
• Use a trim clip removal tool or flat-blade screwdriver to release the ABS wheel speed sensor wire clips from the strut.
• Do not pull on the ABS wire. Move the wiring aside gently.

Step 4: Disconnect the Stabilizer Bar Link

• The stabilizer bar link is the short rod that connects the sway bar to the strut and helps reduce body roll.
• Use an 18mm wrench on the link nut.
• If the stud spins, hold the center of the stud with a 6mm Allen key socket while removing the nut with the 18mm wrench.
• Move the stabilizer bar link away from the strut.

Step 5: Support the Steering Knuckle

• Use the floor jack lightly under the lower control arm or steering knuckle area.
• Do not lift the vehicle off the jack stands.
• This support prevents the brake hose and axle from being pulled when the strut is removed.

Step 6: Remove the Strut-to-Knuckle Bolts

• Spray the strut-to-knuckle nuts and bolts with penetrating oil.
• Use a 21mm socket and 21mm wrench to remove the two strut-to-knuckle nuts and bolts.
• Use a rubber mallet to tap the bolts out if needed.
• Use a pry bar 18-inch carefully to separate the strut from the knuckle.
• Keep the knuckle supported so it does not drop outward.

Step 7: Remove the Upper Strut Mount Nuts

• Open the hood.
• Locate the three upper strut mount nuts at the top of the strut tower.
• Use a 13mm socket and 3/8-inch drive ratchet to remove the three upper strut mount nuts.
• Hold the strut with one hand while removing the last nut.
• Lower the strut assembly out through the wheel opening.

Step 8: Transfer Parts Only If Needed

• If using a complete strut assembly, skip spring transfer and install the new assembly.
• If reusing the spring, use a strut spring compressor (specialty) exactly as its instructions describe.
• Use a 21mm socket to remove the center strut shaft nut only after the spring is fully compressed.
• For a beginner, this step is not recommended because the spring stores dangerous energy.

Step 9: Install the New Strut Assembly

• Guide the new strut assembly into the strut tower from the wheel opening.
• Install the three new upper strut mount nuts by hand first.
• Use a 13mm socket and 1/2-inch drive torque wrench to tighten the upper strut mount nuts to Torque to 35 Nm (26 ft-lbs).
• Make sure the strut bracket faces the steering knuckle correctly.

Step 10: Attach the Strut to the Steering Knuckle

• Line up the paint marks using your paint marker reference.
• Use the floor jack to raise or lower the knuckle slightly until the bolt holes line up.
• Install new strut-to-knuckle bolts and nuts by hand.
• Use a 21mm socket, 21mm wrench, and 1/2-inch drive torque wrench to tighten the strut-to-knuckle nuts to Torque to 175 Nm (129 ft-lbs).

Step 11: Reconnect the Stabilizer Bar Link

• Install the stabilizer bar link into the strut bracket.
• Use an 18mm wrench and 6mm Allen key socket if the stud spins.
• Use the 1/2-inch drive torque wrench to tighten the stabilizer bar link nut to Torque to 55 Nm (41 ft-lbs).

Step 12: Reinstall Brake Hose and ABS Wire Brackets

• Use a 13mm socket or 15mm socket to reinstall the brake hose bracket bolt.
• Tighten the bracket bolt snugly to Torque to 12 Nm (106 in-lbs) if using a small torque wrench.
• Use the trim clip removal tool or your fingers to seat the ABS wire clips fully into the strut tabs.
• Turn the steering from side to side by hand and confirm the wire and hose do not stretch or rub.

Step 13: Repeat on the Other Side

• Repeat Steps 2 through 12 on the other front strut.
• Replace front struts in pairs so your Fusion handles evenly.

Step 14: Reinstall Wheels and Lower the Vehicle

• Install the front wheels by hand-starting all lug nuts.
• Use the 19mm lug nut socket to snug the lug nuts in a star pattern.
• Use the floor jack to lift slightly, remove the jack stands, and lower the vehicle fully.
• Use the 19mm lug nut socket and 1/2-inch drive torque wrench to tighten the lug nuts in a star pattern to Torque to 135 Nm (100 ft-lbs).

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✅ After Repair

• ✅ Bounce each front corner lightly. The vehicle should settle quickly without clunking.
• ✅ Turn the steering wheel lock-to-lock and listen for rubbing, popping, or wire tension.
• ✅ Road test slowly first. Listen for clunks over small bumps.
• ✅ Get a professional four-wheel alignment as soon as possible.
• ✅ Recheck lug nut torque after 25-50 miles using a 19mm lug nut socket and 1/2-inch drive torque wrench.

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💰 DIY vs Shop Cost

Shop Cost: $850-$1,400 (parts + labor + alignment)

DIY Cost: $300-$650 (parts only, alignment extra)

You Save: $400-$750 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2.5-4.0 hours.

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