🔧 Fusion - Rear Brake Pad Replacement

This repair replaces the rear brake pads on your Fusion. Rear pads wear down over time, and replacing them before they get too thin helps protect the rotors and keeps braking safe.

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

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⚠️ Safety & Precautions

• ⚠️ Your Fusion uses a rear electronic parking brake, so the parking brake motors must be put into service mode before pushing the caliper pistons back.
• ⚠️ Do not push the rear caliper piston back unless the electronic parking brake is in service mode, or damage can occur.
• ⚠️ Work on a flat, solid surface. Never rely on a jack alone; always support the vehicle with jack stands.
• ⚠️ Brake dust can be harmful. Wear safety glasses and a dust mask, and avoid blowing dust with compressed air.
• ⚠️ Battery disconnect is not required for this job.

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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
• Rear brake caliper piston compression tool (specialty)
• Flat-blade screwdriver
• Brake parts cleaning brush
• Brake cleaner spray
• Bungee cord
• Dust mask
• 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 and leave the transmission in Park.
• Do not set the parking brake before starting this repair.
• Place wheel chocks in front of the front wheels.
• A torque wrench tightens bolts to a precise force so they are not too loose or too tight.
• Service mode retracts the electronic parking brake motors so the rear calipers can be serviced safely.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Put the Electronic Parking Brake in Service Mode

• Sit in the driver seat and turn the ignition on without starting the engine.
• Press and hold the accelerator pedal fully down.
• Push and hold the electronic parking brake switch down in the release direction.
• While holding both, turn the ignition off and then back on.
• Keep holding until the parking brake warning light flashes or a service mode message appears.
• Release the pedal and switch after service mode is active.
• Listen for the rear motors retracting.

Step 2: Loosen the Rear Wheel Lug Nuts

• Use a 19mm lug nut socket and 1/2-inch drive breaker bar to loosen each rear wheel lug nut about half a turn.
• Do this before lifting the vehicle so the wheels do not spin.

Step 3: Lift and Support the Rear of the Vehicle

• Use a floor jack rated 2-ton minimum to lift the rear of your Fusion at the proper rear jacking point.
• Place jack stands rated 2-ton minimum under the rear support points.
• Lower the vehicle gently onto the jack stands.
• Lightly shake the vehicle by hand to confirm it is stable.

Step 4: Remove the Rear Wheels

• Use the 19mm lug nut socket 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 a 13mm socket to remove the two rear caliper slide pin bolts.
• If the slide pins spin, hold the pin with a 15mm wrench while removing the bolt with the 13mm socket.
• Lift the caliper off the bracket.
• Use a bungee cord to hang the caliper from the suspension spring or arm.
• Do not let the caliper hang by the brake hose.

Step 6: Remove the Old Brake 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 metal pad clips from the bracket.
• Compare the old pads to the new rear brake pads to confirm the shape matches.

Step 7: Clean the Caliper Bracket

• Wear safety glasses, nitrile gloves, and a dust mask.
• Use brake cleaner spray and a brake parts cleaning brush to clean the pad contact areas on the caliper bracket.
• Do not spray brake cleaner on painted body panels.
• Clean brackets help prevent brake noise.

Step 8: Install the New Brake Hardware

• Press the new rear brake pad hardware clips into the caliper bracket by hand.
• Apply a thin layer of brake lubricant to the areas where the pad ears touch the clips.
• Do not get lubricant on the brake pad friction material or rotor face.

Step 9: Compress the Rear Caliper Piston

• Check that the electronic parking brake is still in service mode.
• Use the rear brake caliper piston compression tool to slowly push the piston straight back into the caliper.
• A caliper piston compression tool presses the piston back evenly so the thicker new pads will fit.
• Go slowly and make sure the brake hose does not twist.

Step 10: Install the New Rear Brake Pads

• Slide the new rear brake pads into the caliper bracket by hand.
• Make sure the pads sit fully in the hardware clips and move smoothly.
• If a pad is tight, remove it and clean the bracket again with the brake parts cleaning brush.

Step 11: Reinstall the Rear Caliper

• Place the caliper over the new pads by hand.
• Install the caliper slide pin bolts by hand first to avoid cross-threading.
• Use the 13mm socket and 15mm wrench if needed to tighten the caliper slide pin bolts.
• Torque to 35 Nm (26 ft-lbs).

Step 12: Repeat on the Other Rear Side

• Use the same tools and steps on the opposite rear brake assembly.
• Always replace rear brake pads in pairs so braking stays even.

Step 13: Reinstall the Rear Wheels

• Place each wheel back onto the hub by hand.
• Install the lug nuts by hand first.
• Use the 19mm lug nut socket to snug the lug nuts in a star pattern.

Step 14: Lower the Vehicle and Torque the Wheels

• Use the floor jack rated 2-ton minimum to lift the rear slightly and remove the jack stands rated 2-ton minimum.
• Lower the vehicle until the tires touch the ground.
• Use a 1/2-inch drive torque wrench and 19mm lug nut socket to tighten the lug nuts in a star pattern.
• Torque to 135 Nm (100 ft-lbs).

Step 15: 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 up in the apply direction.
• While holding both, turn the ignition off and then back on.
• Keep holding until the parking brake warning light stops flashing or the service mode message clears.
• Release the pedal and switch.
• Apply and release the parking brake once to confirm normal operation.

Step 16: Pump the Brake Pedal

• Before moving the vehicle, press the brake pedal several times until it feels firm.
• This seats the caliper pistons against the new pads.
• Do not drive until the brake pedal feels normal.

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✅ After Repair

• Start your Fusion and confirm no brake warning messages remain.
• Test the brake pedal while parked. It should feel firm, not soft or sinking.
• Drive slowly in a safe area and test the brakes gently.
• Bed in the pads with several gentle stops from about 30 mph, allowing the brakes to cool between stops.
• Avoid hard braking for the first 100-200 miles unless needed for safety.
• Recheck lug nut torque after the first short drive: 135 Nm (100 ft-lbs).

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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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