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Ford Fusion Rear Brake Pads Replacement Guide
How to change the rear disc brake pads on a 2nd generation 2013 to 2016 Ford Fusion with photo illustrated steps.

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2014 Fusion Rear Wheel
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Slightly Loosen 5 Lug Nuts
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Raise Rear of Vehicle

This automotive maintenance tutorial was specifically written to assist owners of the second generation (2013, 2014, 2015, 2016 and perhaps also the revised 2017) Ford Fusion sedan in changing the rear disc brake pads.

Owners of other Ford or Lincoln vehicles such as the Focus, Fiesta, C-Max, Mustang, Escape, Transit Connect, Edge, Flex, Explorer, Expedition, Taurus, F-150, EcoSport, MKC, MKZ, MKS, MKX, MKT and the Navigator may also find these DIY instructions to be helpful.

The tools needed to complete this procedure include a lug nut wrench, a floor jack, two jack stands, a flathead screwdriver, a 7mm Allen Key wrench or a 7mm hex head socket, a disc brake piston tool (Lisle # 28600) and a tube of high temperature synthetic brake parts lubricant grease.

A few compatible replacement sets of new rear brake pads with their part numbers include the following: Wagner ZD1665,     Power Stop 16-1665 Z16, Motorcraft BR-1161B, Bendix D1665, Motorcraft BRF30, TRW TPC1665 and Centric 105.16650.


Please verify the correct replacement part numbers for your Fusion by calling a Ford dealership's parts counter, contacting an auto parts stores or by using the Amazon Part Finder website.

The compatible part numbers may vary depending on your Fusion's model year, trim level and whether it is a hybrid.

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Spin Off 5 Lug Nuts
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Caliper, Bracket & Rotor
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Rear Brake Caliper
Park the vehicle on a level surface and make sure that the emergency / parking brake is not engaged.

If your Fusion is equipped with an electronic parking brake or "EPB", follow these steps to place the rear brakes in "maintenance mode". 1. Set the ignition switch to "On" but do not start the engine. 2. Press and hold down the accelerator (gas) pedal and hold the EPB switch down to the release position. 3. Set the ignition switch to "Off" and then to "On" within 5 seconds. Continue to hold the accelerator pedal down and hold the EPB switch down. You will see the yellow EPB indicator light on the gauges and "Maintenance Mode" will display on the message center. 4. Switch the ignition to "Off" and release both the gas pedal and EPB switch.

Chock both sides of the front wheels to make sure that the vehicle won't move while you are replacing the rear brake pads.

Slightly loosen the five lug nuts on the rear wheel by turning them counterclockwise with the tire iron.

Raise the rear of the vehicle and securely support it with the two jack stands.

I prefer to work on one side of the car at a time to keep three wheels on the ground for extra safety.

Spin off the 5 lug nuts and set them aside in a safe place.

Pull off the rear wheel to reveal the caliper, bracket, rotor and suspension.

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Pry Out Plastic Dust Caps
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Caliper Bolt Cover Removed
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Remove 2nd Dust Cap
Gently pry out the round plastic dust caps on the back of the caliper with a flathead screwdriver.

Set the dust covers aside in a safe place.

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7mm Hex Head Bolt
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Loosen Clockwise
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Loosen Upper 7mm Hex
Loosen the two caliper bolts by turning them clockwise (as seen from the outside of the car) with a 7mm Allen Key wrench or a 7mm hex head socket.
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Spin Out Clockwise
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Caliper Bolt / Slider Pin
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Pry Out Upper Caliper Bolt
Spin out the two caliper bolts / caliper slider pins and set them aside in a safe place.

You may need to use a flathead screwdriver to pry the caliper bolt / slider pin out of the bracket.

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Upper Bolt / Slider Pin
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Pry Off Metal Spring Clip
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Spring Clip Removed
For the next step, I'd recommend wearing protective eye wear.

The spring clip might pop off and hit in the face or eyes.

Very carefully pry off the metal spring clip from the outer edge of the caliper with a flathead screwdriver.

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Pull Off Brake Caliper
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Screw In Type Caliper Piston
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Remove Old Outer Pad
Pull the brake caliper off the old pads and out of the bracket.

Remove the old inner and outer brake pads out of the bracket.

Edit - I mistakenly thought the new Fusion had screw-in type caliper pistons. The shop manual specifies that they just need to be compressed in. Here is a direct quote from the shop manual: "the brake caliper piston must be compressed into the caliper housing. The brake caliper piston does not have to be rotated while compressing the piston."

The second generation Fusion is equipped with "screw-in" type rear caliper pistons.

You will either need a caliper piston tool or a pair of needle nose pliers to turn back the caliper piston.

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Pull Out Old Inner Pad
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Lisle # 28600 Piston Tool
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Test Fit Sides Of Tool
If you have a caliper piston tool such as the Lisle # 28600, test fit each side of the tool to find the side that has the best grip on the piston.

Attach the piston tool to an extension bar and the ratcheting wrench.

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Twist Off Brake Fluid Cap
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Turn Back Caliper Piston
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Or Use Needle Nose Pliers
Move to the right rear area of the engine bay and twist off the brake fluid cap in the counterclockwise direction.

Removing the reservoir cap will allow the brake fluid to more easily travel back through the lines when you turn back the pistons.

Slowly turn back the piston in the clockwise direction to retract it so that caliper will fit over the thicker new brake pads.

If you don't have a disc brake piston tool, you can also use a pair of needle nose pliers.

Replace the reservoir cap as soon as possible by twisting it on in the clockwise direction. Brake fluid is hygroscopic, which means it readily absorbs moisture from the air.



 

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Replace Brake Fluid Cap
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Install New Brake Pads
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Push Pads Against Rotor
Thoroughly clean off the brake rotor, caliper bracket, brake caliper assembly and the lug nut studs with brake parts cleaner spray. Do not use compressed air or blow with your mouth to clean off the brake parts since breathing in brake dust can be harmful to your health. Brake dust may be carcinogenic (cancer causing) if inhaled.

If your Fusion previously exhibited shuddering, pulsating, or vibrations in the rear end during braking, you may need to have your rotors "turned" (resurfaced) or just replace them with brand new rotors. If this is the car's first rear brake job and the rotors appear to be in excellent condition, you should be able to just change the pads with great results.

To remove the existing rotors and install new ones, remove the two bolts on the rear of the caliper bracket that attach it to the steering knuckle. Then loosen the old rotor with a rubber mallet, pull it off, and slide the new one in its place.

Apply a thin layer of brake caliper grease to any area where there is metal to metal contact such as the outer lip of the caliper pistons. Do not apply brake parts lubricant to the friction surface of the new pads or to the rotor.

Install the new inner and outer brake pads in to the bracket.

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Lower Caliper Over Pads
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Lubricate Caliper Slider Pins
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Spin In Counterclockwise
Carefully lower the caliper over the rotor and in to the bracket.

If the caliper won't fit over the new pads, you may need to turn back the piston a bit further.

In order for the caliper to operate smoothly, the two caliper slider pins / bolts need to be well lubricated.

Apply a thin layer of brake parts lubricant grease to the smooth parts of the two slider pins / bolts.

Re-insert the two caliper bolts / slider pins and spin them in a few turns in the counterclockwise direction by hand to prevent them from becoming cross threaded.

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Spin In Lower Caliper Bolt
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Tighten Counterclockwise
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Torque To 20-25 Ft-Lbs
Tighten the two caliper bolts in the counterclockwise direction (as seen from the outside of the car) with the 7mm Allen Key wrench or a 7mm hex head socket to just past hand tight or about 20 to 25 ft-lbs of torque.

Double check that the two caliper bolts are tight before moving on to the next steps.

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Rubber Valve Cap
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Brake Fluid Bleeder Valve
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Re-Attach Metal Spring Clip
If your brake pedal previously felt soft or spongy, the brake fluid may be contaminated with water or the brake lines may contain a few air bubbles.

It would be best to bleed the brake lines at this time in order to flush out the old fluid and replace it with fresh DOT 4 brake fluid. For more on this topic, check out my Brake Line Fluid Bleeding With An Assistant DIY Guide or alternatively the Brake Line Fluid Bleeding With A Power Bleeder Guide.

The brake fluid bleeder valve is located underneath a rubber cap on the back side of the caliper right next to the upper caliper bolt.

Carefully re-attach the metal spring clip to the outside edge of the caliper.

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Push In Plastic Dust Caps
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Bolt Covers Replaced
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Push On Rear Wheel
Push the two plastic dust covers back in to place over the caliper bolt housings.

Replace the rear wheel.

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Spin On 5 Lug Nuts
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Slightly Tighten Clockwise
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Torque To 100 ft-lbs
Spin on the five lug nuts in the clockwise direction a few turns by hand to prevent them from becoming cross threaded.

Slightly tighten the lug nuts in the clockwise direction in a "star" or "criss cross" pattern with the lug nut wrench.

Carefully lower the car from the jack stands by using the floor jack.

Continue progressively tightening the 5 lug nuts in a "criss cross or star pattern to about 1/4 turn past hand tight or about 100 ft-lbs (or 135 Nm) of torque. It would be best to use a torque wrench or an impact wrench with a torque stick to properly tighten the lug nuts.

Sit in the driver's seat of the car and firmly press the brake pedal a few times to restore the brake line pressure. Check the brake fluid in the reservoir and verify that it is at the proper level. If it is low, add some DOT 4 fluid.

To deactivate the electronic parking brake's "Maintenance Mode", follow these steps: 1. Switch the ignition to "On" but do not start the engine. 2. Press and hold the accelerator pedal and pull the EPB switch "Up" to the "Apply parking brake" position. Continue to hold down the gas pedal and pull up the EPB switch. 2. Switch the ignition to "Off" and then "On" within 5 seconds. Continue to hold the gas pedal and pull up on the EPB switch. 3. The EPB system will apply the brake and then release it. 4. Release the gas pedal and the EPB switch. The "Maintenance Mode" message should have disappeared from the screen.

To break in your new rear brake pads, just drive normally for the first few hundred miles while trying to avoid any hard or "panic" stops which may glaze over the new pads and cause them to be noisy or not perform as well.

It's also a good idea to regularly check your driveway for drops of brake fluid which may indicate a leak, check the brake fluid level in the reservoir, and also verify that the lug nuts are still tight. Be sure to record the brake pad change in your service records.

For more, check out my other 2013-2016 Ford Fusion DIY Repair & Maintenance Guides.
 

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