🔧 Fusion - Rear Brake Pad Replacement

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

Difficulty Level: Beginner-Intermediate | Estimated Time: 1.5-2.5 hours

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⚠️ Safety & Precautions

• ⚠️ Your Fusion has an electronic parking brake, often called EPB. EPB maintenance mode moves the rear parking brake motors back so the calipers can be serviced safely.
• ⚠️ Do not press the brake pedal while a rear caliper is removed.
• ⚠️ Do not use the parking brake during the repair unless the calipers and pads are fully installed.
• ⚠️ Support the car with jack stands. Never work under or beside a car supported only by a jack.
• ⚠️ Brake dust is harmful. Wear safety glasses and avoid blowing dust with compressed air.
• ⚠️ Battery disconnect is not required for this pad replacement.

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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
• 13mm socket
• 15mm wrench
• 3/8-inch drive ratchet
• Flat-blade screwdriver
• Disc brake pad spreader tool
• Brake caliper hanger hook
• Nylon brush
• Brake cleaner spray
• Shop towels
• 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 pad hardware kit - Qty: 1
• Brake lubricant - Qty: 1
• Brake cleaner spray - Qty: 1

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📋 Before You Begin

• Park your Fusion on level ground.
• Put the transmission in Park.
• Chock the front wheels with wheel chocks.
• Release the electronic parking brake before entering maintenance mode.
• Open the brake fluid reservoir cap under the hood. Lay a shop towel around it in case fluid rises when the caliper pistons are pushed back.
• EPB maintenance mode is required before removing the rear calipers.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Put the EPB into Maintenance Mode

• Sit in the driver seat with the doors closed.
• Turn the ignition ON without starting the engine. For push-button start, press the START button without pressing the brake pedal.
• Make sure the parking brake is released.
• Press and hold the accelerator pedal fully to the floor.
• Push and hold the EPB switch downward in the release position.
• While holding both, turn the ignition OFF, then turn the ignition back ON within about 5 seconds.
• Keep holding the accelerator pedal and EPB switch until the instrument cluster shows a parking brake maintenance mode message.
• Release the accelerator pedal and EPB switch.
• Listen for the 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 this while the rear tires are still touching the ground.
• Do not fully remove the lug nuts yet.

Step 3: Lift and Support the Rear of the Car

• Use a floor jack to lift the rear of your Fusion at the proper rear jacking point.
• Place jack stands under the approved rear support points.
• Lower the car gently onto the jack stands.
• Use the floor jack as a backup support, but do not rely on it alone.

Step 4: Remove the Rear Wheels

• Use the 19mm lug nut socket to remove the loosened lug nuts.
• Remove both rear wheels.
• Slide one wheel under the side of the car as an extra safety backup.

Step 5: Remove the Rear Caliper

• Work on one side at a time so the other side stays assembled as a reference.
• Use a 15mm wrench to hold the caliper slide pin steady.
• Use a 13mm socket and 3/8-inch drive ratchet to remove the upper and lower rear caliper bolts.
• Lift the caliper off the bracket carefully.
• Hang the caliper with a brake caliper hanger hook.
• Do not let the caliper hang by the brake hose.

Step 6: Remove the Old Pads and Hardware

• Use your hands or a flat-blade screwdriver to slide the old brake pads out of the caliper bracket.
• Use the flat-blade screwdriver to remove the old stainless pad clips from the bracket.
• Look at the old pads. Uneven wear can mean stuck slide pins or caliper issues.
• Take a quick photo before removal.

Step 7: Clean the Caliper Bracket

• Use brake cleaner spray and shop towels to clean the caliper bracket.
• Use a nylon brush to clean the pad contact areas where the clips sit.
• Do not get brake lubricant on the rotor friction surface.
• The rotor friction surface is the shiny face the brake pad presses against.

Step 8: Install New Pad Hardware

• Install the new rear brake pad hardware clips by hand into the caliper bracket.
• Apply a thin layer of brake lubricant to the pad contact points on the clips.
• Do not apply grease to the pad friction material.
• The friction material is the rough braking surface of the pad.

Step 9: Compress the Rear Caliper Piston

• Use a disc brake pad spreader tool to slowly push the caliper piston straight back into the caliper bore.
• The caliper bore is the round opening where the piston slides in and out.
• Watch the brake fluid reservoir under the hood while compressing the piston.
• If brake fluid gets close to overflowing, remove a small amount with a clean suction tool.
• Do not twist the piston on this EPB setup after maintenance mode has retracted the actuator.

Step 10: Install the New Rear Brake Pads

• Slide the new rear brake pads into the caliper bracket by hand.
• Make sure the pads move freely in the new hardware clips.
• If a pad is tight, remove it and recheck the clip seating.
• Pads should slide, not jam.

Step 11: Reinstall the Rear Caliper

• Lower the caliper over the new pads by hand.
• Use a 15mm wrench to hold the slide pin steady.
• Use a 13mm socket and 3/8-inch drive ratchet to install the caliper bolts.
• Use a torque wrench with the 13mm socket to tighten the rear caliper bolts to 35 Nm (26 ft-lbs).

Step 12: Repeat on the Other Rear Side

• Repeat Steps 5 through 11 on the opposite rear brake.
• Use the same 13mm socket, 15mm wrench, brake cleaner spray, nylon brush, brake lubricant, and disc brake pad spreader tool.
• Replace rear brake pads in pairs only.

Step 13: Reinstall the Rear Wheels

• Install each rear wheel by hand.
• Thread the lug nuts by hand first to avoid cross-threading.
• Use the 19mm lug nut socket and ratchet to snug the lug nuts in a star pattern.
• Raise the car slightly with the floor jack, remove the jack stands, and lower the car to the ground.
• Use a 1/2-inch drive torque wrench and 19mm lug nut socket to tighten the lug nuts to 135 Nm (100 ft-lbs).

Step 14: Exit EPB Maintenance Mode

• Turn the ignition ON without starting the engine.
• Press and hold the accelerator pedal fully to the floor.
• Pull and hold the EPB switch upward in the apply position.
• While holding both, turn the ignition OFF, then turn the ignition back ON within about 5 seconds.
• Keep holding the accelerator pedal and EPB switch until the instrument cluster shows the parking brake maintenance mode has ended.
• Release the accelerator pedal and EPB switch.
• Apply and release the parking brake once to confirm normal operation.

Step 15: Pump the Brake Pedal

• Use your foot to slowly press the brake pedal several times.
• The pedal may go low at first. Keep pumping until it feels firm.
• Do not drive until the brake pedal feels firm.
• Reinstall and tighten the brake fluid reservoir cap by hand.

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✅ After Repair

• ✅ Start your Fusion and check that no brake warning message remains on the dash.
• ✅ Test the electronic parking brake by applying and releasing it while parked.
• ✅ Check behind both rear wheels for brake fluid leaks.
• ✅ Drive slowly in a safe area and make several gentle stops.
• ✅ Bed in the pads by making 8-10 smooth stops from about 30 mph to 5 mph, allowing a short cool-down between stops.
• ✅ Avoid hard braking for the first 100-200 miles unless needed for safety.

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💰 DIY vs Shop Cost

Shop Cost: $250-$450 (parts + labor)

DIY Cost: $45-$110 (parts only)

You Save: $140-$340 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.0-1.5 hours.

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🎯 Ready to get started?

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