🔧 Fusion - Rear Brake Pad & Rotor Replacement

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

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

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⚠️ Safety & Precautions

• ⚠️ Your Fusion has an electronic parking brake. Do not push the rear caliper pistons back unless the parking brake is in service mode.
• ⚠️ Work on level ground and support the car with jack stands. Never rely on a jack alone.
• ⚠️ Brake dust can be harmful. Wear safety glasses and a dust mask, and do not blow dust with compressed air.
• ⚠️ Brake fluid can damage paint. Wipe spills immediately with a clean shop towel.
• ⚠️ Battery disconnect is not required for this job when using the correct EPB service mode procedure.

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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
• Safety glasses
• Nitrile gloves
• Dust mask
• 1/2-inch drive breaker bar
• 1/2-inch drive torque wrench
• 3/8-inch drive ratchet
• 19mm lug nut socket
• 13mm socket
• 15mm wrench
• 18mm socket
• Flathead screwdriver
• Brake caliper piston compression tool
• Wire brush
• Brake parts cleaning brush
• Rubber mallet
• Bungee cord
• Shop towels
• Brake cleaner spray
• High-temperature brake lubricant

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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 - Replace in pairs - Qty: 2
• Rear brake hardware kit - Qty: 1
• Brake cleaner spray - Qty: 1
• High-temperature brake lubricant - Qty: 1

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📋 Before You Begin

• Park your Fusion on level ground.
• Make sure the transmission is in Park.
• Do not apply the parking brake before starting this repair.
• Place wheel chocks in front of both front tires. Wheel chocks are blocks that keep the car from rolling.
• Open the hood and loosen the brake fluid reservoir cap slightly. This helps fluid move back into the reservoir when the caliper piston is compressed.
• Check the brake fluid level. If it is near the top, remove a small amount with a clean suction tool to prevent overflow.
• Put the electronic parking brake into service mode before lifting the rear wheels.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Enter Electronic Parking Brake Service Mode

• Turn the ignition ON without starting the engine. On push-button models, press START without pressing the brake pedal.
• Press and hold the accelerator pedal fully down.
• Press and hold the electronic parking brake switch downward in the RELEASE position.
• While holding both, turn the ignition OFF, then turn it back ON within about 5 seconds.
• Keep holding the accelerator pedal and parking brake switch until the parking brake motors retract and a message appears on the dash.
• Release the pedal and switch after the system finishes moving.
• Listen for the rear motors.

Step 2: Loosen the Rear Lug Nuts

• Use the 19mm lug nut socket and 1/2-inch drive breaker bar to loosen each rear lug nut about 1/2 turn.
• Do not remove the lug nuts yet.

Step 3: Raise and Support the Rear of the Car

• Use the floor jack at the proper rear jacking point to lift the rear of your Fusion.
• Place jack stands under the rear support points.
• Lower the car gently onto the jack stands.
• Lightly shake the car to confirm it is stable before working underneath or near the wheels.

Step 4: Remove the Rear Wheels

• Use the 19mm lug nut socket and 3/8-inch drive ratchet to remove the rear lug nuts.
• Remove both rear wheels and set them flat aside.

Step 5: Remove the Rear Caliper

• Use the 15mm wrench to hold the caliper slide pin if it spins.
• Use the 13mm socket and 3/8-inch drive ratchet to remove the two rear caliper bolts.
• Lift the caliper off the brake pads.
• 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 flathead screwdriver to gently pry the old brake pads out of the caliper bracket.
• Use the flathead screwdriver to remove the old stainless brake pad clips.
• Brake pad clips are thin metal guides that help the pads slide smoothly.
• Remember which direction the old pads and clips were installed before removing them.

Step 7: Remove the Caliper Bracket

• Use the 18mm socket and 1/2-inch drive breaker bar to remove the two rear caliper bracket bolts.
• Remove the caliper bracket from the rear knuckle.
• These bolts may be tight, so keep the socket straight to avoid rounding the bolt heads.

Step 8: Remove the Old Rotor

• Pull the old rear rotor straight off the hub by hand.
• If the rotor is stuck, use the rubber mallet to tap around the rotor hat until it breaks loose.
• Do not strike the wheel studs with the mallet.
• Rust can hold the rotor tight.

Step 9: Clean the Hub Face

• Use the wire brush to clean rust from the wheel hub face.
• Use brake cleaner spray and shop towels to wipe the hub clean.
• The new rotor must sit flat against the hub to prevent brake vibration.

Step 10: Install the New Rotor

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

Step 11: Clean and Prepare the Caliper Bracket

• Use the brake parts cleaning brush and brake cleaner spray to clean the caliper bracket pad contact areas.
• Use the wire brush to remove rust where the brake hardware clips sit.
• Apply a thin layer of high-temperature brake lubricant to the bracket areas under the new clips.
• Do not get lubricant on the rotor or pad friction material.

Step 12: Reinstall the Caliper Bracket

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

Step 13: Install New Brake Hardware and Pads

• Snap the new brake pad clips into the caliper bracket by hand.
• Apply a very thin layer of high-temperature brake lubricant where the pad ears contact the clips.
• Install the new inner and outer brake pads into the bracket.
• The pad ears are the small tabs at each end of the brake pad backing plate.
• Make sure the pads slide freely in the clips.

Step 14: Compress the Rear Caliper Piston

• Use the brake caliper piston compression tool to slowly press the rear caliper piston straight back into the caliper.
• A piston compression tool pushes the caliper piston inward to make room for the thicker new pads.
• Go slowly and watch the brake fluid reservoir under the hood so it does not overflow.
• If the piston does not move smoothly, stop and recheck that the electronic parking brake is in service mode.

Step 15: Reinstall the Rear Caliper

• Remove the bungee cord and place the caliper over the new pads.
• Start both caliper bolts by hand.
• Use the 15mm wrench to hold the slide pin if needed.
• Use the 13mm socket and 3/8-inch drive torque wrench to tighten the caliper bolts to Torque to 35 Nm (26 ft-lbs).

Step 16: Repeat on the Other Rear Side

• Repeat Steps 5 through 15 on the opposite rear brake.
• Always replace rear pads and rotors in pairs so braking stays even.

Step 17: Reinstall the Rear Wheels

• Remove the temporary lug nut holding each rotor.
• Install both rear wheels.
• 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 18: Lower the Vehicle and Torque the Lug Nuts

• Use the floor jack to lift the car slightly off the jack stands.
• Remove the jack stands.
• Lower the car until the tires touch the ground.
• 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).
• Fully lower the car and remove the jack.

Step 19: Exit Electronic Parking Brake Service Mode

• Turn the ignition ON without starting the engine.
• Press and hold the accelerator pedal fully down.
• Pull and hold the electronic parking brake switch upward in the APPLY position.
• While holding both, turn the ignition OFF, then turn it back ON within about 5 seconds.
• Keep holding until the parking brake motors apply and the dash message clears.
• Release the pedal and switch.

Step 20: Pump the Brake Pedal

• Sit in the driver seat and press the brake pedal slowly several times.
• The pedal may go low at first, then become firm.
• Do not drive until the brake pedal feels firm.

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✅ After Repair

• Check the brake fluid level and reinstall the reservoir cap.
• Start your Fusion and confirm no brake warning lights stay on.
• Apply and release the electronic parking brake two or three times to confirm normal operation.
• Test drive slowly in a safe area and check that the brakes stop smoothly.
• Bed in the new brake pads with 8-10 moderate stops from about 30 mph to 5 mph. Do not come to a complete stop and hold the brake pedal during bedding.
• Avoid hard braking for the first 200 miles unless needed for safety.
• Recheck lug nut torque after the first short drive: Torque to 135 Nm (100 ft-lbs).

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💰 DIY vs Shop Cost

Shop Cost: $350-$600 (parts + labor)

DIY Cost: $120-$250 (parts only)

You Save: $230-$350 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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