🔧 Fusion - Rear Brake Pads & Rotors Replacement

This job replaces the rear brake pads and brake rotors on your Fusion. The rear brakes use an electric parking brake, so the parking brake motors must be placed in service mode before the calipers are removed.

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

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⚠️ Safety & Precautions

• ⚠️ Your Fusion has an electric parking brake. Do not force the rear caliper pistons in unless the parking brake is in service mode.
• ⚠️ Your Fusion is a plug-in hybrid. Do not touch orange high-voltage cables or high-voltage components.
• ⚠️ Work on a flat, solid surface and support the car with jack stands before removing wheels.
• ⚠️ Do not press the brake pedal while a caliper is removed.
• ⚠️ Wear safety glasses and gloves. Brake dust and rust can irritate skin and eyes.
• ⚠️ Battery disconnect is not normally required for this brake job if you use the correct electric parking brake service mode.

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🔧 Required Tools

You'll need the following tools for this repair:

• Electronic parking brake service mode capable scan tool (specialty)
• 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 wrench
• 18mm socket
• Brake caliper piston compression tool (specialty)
• Flat-blade screwdriver
• Wire brush
• Brake cleaner spray
• Shop towels
• Bungee cord
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake rotors - Qty: 2
• Rear brake hardware kit - Qty: 1
• Rear brake caliper bracket bolts - Qty: 4
• High-temperature brake lubricant - Qty: 1
• DOT 4 brake fluid - Qty: 1 pint

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📋 Before You Begin

• 🅿️ Park your Fusion on level ground, shift to Park, and leave the ignition off at first.
• 🧱 Place wheel chocks in front of the front tires.
• 🔍 Check the brake fluid reservoir. If it is at the MAX line, remove a small amount with a clean suction tool before compressing calipers.
• 🧰 A scan tool is the safest method. A scan tool is a handheld device that talks to the car’s computers and can command the electric parking brake into service mode.
• ⚙️ Use the scan tool to enter electric parking brake maintenance/service mode before removing rear calipers.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Put the Electric Parking Brake in Service Mode

• Use the electronic parking brake service mode capable scan tool and connect it to the OBD-II port under the driver side dash.
• Turn the ignition on without pressing the brake pedal. On your Fusion, this wakes the vehicle without starting the gas engine.
• On the scan tool, select the parking brake or brake service function, then choose rear brake service mode or maintenance mode.
• Wait until the scan tool confirms the rear parking brake motors have fully retracted.
• Listen for both rear motors.

Step 2: Loosen the Rear Wheel Lug Nuts

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

Step 3: Raise and Support the Rear of the Vehicle

• Use the floor jack at the approved rear lift point to raise the rear of your Fusion.
• Place jack stands under the approved rear support points.
• Lower the car gently onto the stands using the floor jack.
• Shake the vehicle lightly by hand to confirm it is stable before working near the brakes.

Step 4: Remove the Rear Wheels

• Use the 19mm lug nut socket and 3/8-inch drive ratchet to remove the loosened lug nuts.
• Remove both rear wheels and place them flat under the side of the vehicle as an extra safety backup.

Step 5: Remove the Rear Caliper

• Use the 13mm socket to remove the two rear caliper slide pin bolts.
• If the slide pin spins, hold it steady with the 15mm wrench while removing the bolt with the 13mm socket.
• Lift the caliper off the bracket by hand.
• Use the bungee cord to hang the caliper from the suspension spring or control arm.
• Do not let the caliper hang by the rubber brake hose.

Step 6: Remove the Old Brake Pads and Hardware

• Use the flat-blade screwdriver to gently pry the old brake pads out of the caliper bracket.
• Remove the stainless pad clips from the bracket by hand or with the flat-blade screwdriver.
• Inspect the caliper slide pins. They should move smoothly by hand.

Step 7: Remove the Caliper Bracket

• Use the 18mm socket and 1/2-inch drive breaker bar to remove the two caliper bracket bolts.
• Remove the caliper bracket from the rear knuckle.
• Discard the old bracket bolts if your replacement hardware includes new bolts.

Step 8: Remove the Rear Rotor

• Pull the rotor straight off the wheel hub by hand.
• If the rotor is stuck from rust, tap around the rotor hat with light hand force while pulling outward.
• Do not strike the parking brake motor or caliper wiring.

Step 9: Clean the Hub and Bracket

• Use the wire brush to clean rust from the wheel hub face.
• Use brake cleaner spray and shop towels to wipe the hub clean.
• Use the wire brush to clean the pad contact areas on the caliper bracket.
• Clean hubs prevent brake vibration.

Step 10: Install the New Rotor

• Use brake cleaner spray and shop towels to clean the protective oil off both sides of the new rotor.
• Slide the new rotor onto the hub by hand.
• Install one lug nut backward by hand to hold the rotor flat while you work.

Step 11: Reinstall the Caliper Bracket

• Position the caliper bracket over the new rotor.
• Install the caliper bracket bolts by hand first to avoid cross-threading.
• Use the 18mm socket and 1/2-inch drive torque wrench to tighten the bracket bolts.
• Torque to 103 Nm (76 ft-lbs).

Step 12: Install New Brake Hardware and Pads

• Snap the new brake pad clips from the rear brake hardware kit into the caliper bracket by hand.
• Apply a thin layer of high-temperature brake lubricant to the pad ears where they touch the clips.
• Do not put lubricant on the pad friction surface or rotor face.
• Slide the new rear brake pads into the bracket by hand.

Step 13: Compress the Rear Caliper Piston

• Use the brake caliper piston compression tool to slowly press the caliper piston back into the caliper bore.
• The caliper bore is the round opening where the piston slides in and out.
• Because the electric parking brake is in service mode, the piston should compress smoothly.
• Stop if heavy force is needed. Recheck that service mode is active.

Step 14: Reinstall the Rear Caliper

• Place the caliper over the new brake pads by hand.
• Install the two caliper slide pin bolts by hand first.
• Hold the slide pin with the 15mm wrench if needed.
• Use the 13mm socket and 3/8-inch drive torque wrench to tighten the slide pin bolts.
• Torque to 35 Nm (26 ft-lbs).

Step 15: Repeat on the Other Rear Side

• Use the same tools and steps on the opposite rear brake.
• Replace both rear rotors and both sets of pads at the same time for even braking.

Step 16: Reinstall the Rear Wheels

• Remove the backward lug nut holding each rotor using the 19mm lug nut socket.
• Install the wheels by hand.
• Thread all lug nuts by hand first.
• Use the 19mm lug nut socket and 3/8-inch drive ratchet to snug the lug nuts in a star pattern.

Step 17: Lower the Vehicle and Torque the Lug Nuts

• Use the floor jack to raise the vehicle slightly off the jack stands.
• Remove the jack stands.
• Lower your Fusion to the ground with the floor jack.
• Use the 19mm lug nut socket and 1/2-inch drive torque wrench to torque the lug nuts in a star pattern.
• Torque to 135 Nm (100 ft-lbs).

Step 18: Exit Electric Parking Brake Service Mode

• Use the electronic parking brake service mode capable scan tool to exit rear brake service mode.
• Wait until the scan tool confirms the electric parking brake motors have returned to normal operation.
• Apply and release the parking brake once using the parking brake switch.

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✅ After Repair

• 🦶 Before moving the car, press the brake pedal slowly several times until it feels firm.
• 🧪 Check the brake fluid level and top off with DOT 4 brake fluid only if needed.
• 🔍 Look behind both rear wheels for leaks or loose parts.
• 🅿️ Test the electric parking brake. Apply it, release it, and confirm no warning message stays on.
• 🚗 Perform a slow test drive in a safe area. Make several gentle stops before normal driving.
• 🔥 Bed in the new pads gently: avoid hard braking for the first 100-200 miles unless needed for safety.

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💰 DIY vs Shop Cost

Shop Cost: $450-$750 (parts + labor)

DIY Cost: $160-$320 (parts only)

You Save: $290-$430 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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🎯 Ready to get started?

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