How to Change a Ford Fusion's Rear Brakes

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Introduced in the 2006 model year, the Ford Fusion rapidly became one of Ford’s top-selling cars. With styling cues taken from many European sedans, the Fusion brings with it design elements never before seen in a Ford car. The Fusion also borrows heavily on European design and technology in the brake system. However, do not let that scare you away from performing a brake job on a Fusion. Despite the fancy background, the systems are essentially the same from a mechanic’s point of view.

Things You'll Need

  • Safety glasses
  • Two wheel chocks
  • Lug wrench
  • Jack
  • Two Jack stands
  • Drain pan
  • Brake clean
  • Socket set
  • White lithium grease
  • Brake caliper piston tool
  • Put your safety glasses on. Place the wheel chocks in the front and back of the driver-side front wheel.

  • Loosen the rear wheel lug nuts with the lug wrench.

  • Slide the jack under the rear and raise it up until you can rest it safely on the jack stands. Once the jack stands are in place, lower the car onto them.

  • Remove the lug nuts and wheel. Place the drip pan under the brake assembly on the left side of the car.

  • Spray the brakes down with brake cleaner, making sure to get all the brake dust off that you possibly can.

  • Take the socket set and remove the brake caliper bolts. Once the caliper bolts are out, slide the brake caliper outward and off the brake rotor.

  • Remove the retaining clip from the back of the caliper and slide the old brake pads out of the caliper.

  • Slip the rotors off and either machine them or replace them. If the rotors are too thin to machine, they will have to be replaced. Check the minimum thickness number, stamped on the rotor hat, against the rotor’s actual thickness. If the actual thickness is less than 2mm greater than the minimum number, you need new rotors.

  • Spray down the caliper slide pins with brake cleaner, and then lubricate them with white lithium grease.

  • Put the new pads in the brake caliper and reinstall the retaining clip. You may need to use a brake caliper piston tool to push the pistons back in far enough to allow you to put the pads in place.

  • Slip the new or machined rotor back on and use a lug nut to hold it in place so you can slide the brake caliper back into position.

  • Bolt the caliper back on and reinstall the wheel and lug nuts. You will not be able to fully tighten the lug nuts until the Fusion is back on the ground.

  • Repeat steps 4 through 12 on the other side.

  • Jack the car back off the stands, then move the stands and set the car back on the ground. Tighten the lug nuts on both sides.

Tips & Warnings

  • It is best to have the lug nuts re-torqued at a tire shop or Ford Service Department. Under-torqued lug nuts can lead to wheel damage; over-torqued lug nuts can cause your brake rotors to warp.

References

  • Photo Credit Creatas/Creatas/Getty Images
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