🔧 Fusion - Rear Brake Pad & Rotor Replacement

This repair replaces the rear brake pads and rotors on your Fusion. Rear brakes wear down over time, and replacing pads and rotors together helps prevent noise, vibration, and uneven braking.

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

---

⚠️ Safety & Precautions

• ⚠️ Your Fusion uses an electronic parking brake, so the rear calipers must be placed into service mode before removal.
• ⚠️ Do not push the rear caliper piston in until the electronic parking brake is in maintenance mode.
• ⚠️ Always support the vehicle with jack stands. Never work under a vehicle supported only by a jack.
• ⚠️ Brake dust can be harmful. Wear safety glasses and gloves, and avoid blowing dust with compressed air.
• ⚠️ Brake fluid can damage paint. Wipe spills immediately with a clean rag and water.
• ⚠️ Battery disconnect is not required for this repair.

---

🔧 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 wrench
• 18mm socket
• Rear brake caliper piston compressor tool (specialty)
• Flat-blade screwdriver
• Wire brush
• Brake cleaner spray
• Shop rags
• Small bungee cord
• Brake fluid tester or turkey baster
• Nitrile gloves
• Safety glasses

---

🔩 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
• Brake caliper slide pin grease - Qty: 1
• Brake cleaner spray - Qty: 1-2 cans
• DOT 4 brake fluid - Qty: 1 small bottle

---

📋 Before You Begin

• ✅ Park your Fusion on level ground.
• ✅ Leave the ignition off before starting the electronic parking brake service mode steps.
• ✅ Place wheel chocks in front of the front tires.
• ✅ Do not set the parking brake before lifting the rear of the vehicle.
• ✅ Open the hood and check the brake fluid reservoir. If it is full, remove a small amount with a brake fluid tester or turkey baster so it does not overflow when the caliper pistons are compressed.
• ✅ A caliper is the clamp-shaped brake part that squeezes the pads against the rotor.
• ✅ A rotor is the round metal disc behind the wheel.
• ✅ A torque wrench tightens bolts to the correct tightness so they are not too loose or too tight.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Put the Electronic Parking Brake in Maintenance Mode

• Sit in the driver seat with the doors closed.
• Press the brake pedal down firmly.
• Push and hold the electronic parking brake switch downward in the release position.
• While holding the switch down, press the accelerator pedal fully to the floor.
• Keep holding both pedals/switch, then turn the ignition ON without starting the engine.
• Continue holding until the instrument cluster shows a parking brake maintenance mode message.
• Turn the ignition OFF.
• Listen for rear motors retracting.

Step 2: Loosen the Rear Lug Nuts

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

Step 3: Raise and Support the Rear of the Vehicle

• Use the floor jack at the rear jacking point to lift the rear of your Fusion.
• Place jack stands under the correct rear support points.
• Lower the vehicle gently onto the jack stands.
• Lightly shake the vehicle to make sure it is stable.
• Stability matters more than speed.

Step 4: Remove the Rear Wheels

• Use the 19mm lug nut socket to remove the loosened lug nuts.
• Remove both rear wheels and set them flat on the ground.

Step 5: Remove the Rear Caliper

• Use a 13mm socket to remove the two rear caliper guide pin bolts.
• If the guide pin spins, hold it steady with a 15mm wrench.
• Lift the caliper off the bracket.
• Use a small bungee cord to hang the caliper from the suspension.
• Do not let the caliper hang by the brake hose.

Step 6: Remove the Old Brake Pads and Hardware

• Use a flat-blade screwdriver to gently pry the old brake pads out of the caliper bracket.
• Remove the old metal pad clips from the bracket by hand or with the flat-blade screwdriver.
• These clips are called brake hardware. They help the pads slide smoothly.

Step 7: Remove the Rear Caliper Bracket

• Use an 18mm socket and 3/8-inch drive ratchet to remove the two caliper bracket bolts.
• Remove the caliper bracket from the rear knuckle.

Step 8: Remove the Old Rotor

• Pull the rotor straight off the wheel hub by hand.
• If it is stuck, tap the rotor hat area gently with a soft-faced hammer if available.
• Use brake cleaner spray and shop rags to clean loose rust and dust.
• Use a wire brush to clean the wheel hub face until it is smooth.
• A clean hub prevents brake vibration.

Step 9: Prepare the New Rotor

• Use brake cleaner spray and shop rags to clean both sides of the new rotor.
• Slide the new rotor onto the hub.
• Install one lug nut by hand to hold the rotor in place while you work.

Step 10: Clean and Reinstall the Caliper Bracket

• Use a wire brush to clean the pad contact areas on the caliper bracket.
• Install the new brake hardware clips by hand.
• Reinstall the caliper bracket over the rotor.
• Use an 18mm socket and 1/2-inch drive torque wrench to tighten the bracket bolts.
• Torque to 103 Nm (76 ft-lbs)

Step 11: Compress the Rear Caliper Piston

• Use the rear brake caliper piston compressor tool to slowly push the caliper piston back into the caliper.
• The piston is the round part inside the caliper that pushes the brake pad.
• Watch the brake fluid reservoir while compressing the piston.
• If the reservoir gets too full, remove a small amount using the brake fluid tester or turkey baster.
• Do not spill brake fluid on paint.

Step 12: Install the New Brake Pads

• Apply a thin layer of brake caliper slide pin grease to the pad ears where they touch the hardware clips.
• Do not get grease on the pad friction surface or rotor face.
• Install the new inner and outer pads into the caliper bracket by hand.
• Make sure the pads slide freely in the clips.

Step 13: Reinstall the Rear Caliper

• Place the caliper over the new pads and rotor.
• Use a 13mm socket to install the caliper guide pin bolts.
• If the guide pin spins, hold it with a 15mm wrench.
• Use a 3/8-inch drive torque wrench to tighten the guide pin bolts.
• Torque to 35 Nm (26 ft-lbs)

Step 14: Repeat on the Other Rear Side

• Use the same tools and steps on the opposite rear brake.
• Always replace rear pads and rotors in pairs.

Step 15: Reinstall the Rear Wheels

• Remove the temporary lug nut holding each rotor.
• Install each wheel by hand.
• Start all lug nuts by hand to avoid cross-threading.
• Use the 19mm lug nut socket to snug the lug nuts in a star pattern.

Step 16: Lower the Vehicle and Torque the Lug Nuts

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

Step 17: Exit Electronic Parking Brake Maintenance Mode

• Sit in the driver seat with the doors closed.
• Press the brake pedal down firmly.
• Pull and hold the electronic parking brake switch upward in the apply position.
• While holding the switch up, press the accelerator pedal fully to the floor.
• Keep holding both pedals/switch, then turn the ignition ON without starting the engine.
• Continue holding until the instrument cluster indicates the parking brake has exited maintenance mode.
• Turn the ignition OFF.

Step 18: Pump the Brake Pedal

• Before driving, press the brake pedal several times until it feels firm.
• This moves the caliper pistons back into position against the new pads.
• Use DOT 4 brake fluid only if the reservoir level is below the minimum mark.

---

✅ After Repair

• ✅ Start your Fusion and confirm the brake pedal feels firm.
• ✅ Apply and release the electronic parking brake several times to confirm normal operation.
• ✅ Check the brake fluid level and top off with DOT 4 brake fluid if needed.
• ✅ Look behind both rear wheels for brake fluid leaks.
• ✅ Perform a slow test drive in a safe area before normal driving.
• ✅ Bed in the new pads with several gentle stops from 30-35 mph, allowing the brakes to cool between stops.
• ✅ Avoid hard braking for the first 200 miles unless it is an emergency.

---

💰 DIY vs Shop Cost

Shop Cost: $350-$650 (parts + labor)

DIY Cost: $120-$260 (parts only)

You Save: $230-$390 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-2.5 hours.

---

🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.