AfterMarketNews Brake&Frontend BodyShopBusiness Counterman EngineBuilder Fleet Equipment ImportCar Motorcycle & Powersports News Servicio Automotriz Shop Owner Tire Review Tech Shop Tomorrow's Tech Underhood Service Speedville

Servicing Mercedes-Benz AIRMATIC Suspensions

The Mercedes-Benz AIRMATIC suspension system was introduced in 1999 on the S-Class and has subsequently been used on the E-Class and most of the automaker’s SUVs. The system employs electronically controlled air springs that provide an ideal balance...

Read more...

Mazda: Performing Regular Undercar Maintenance

In this article, we’ll take a look at brake and undercar service on the Mazda vehicle lineup, with the footnote that even though this type of work ­becomes routine when you have a preventive maintenance mindset, good work habits from beginning to end...

Read more...

ZF 8-Speed Transmission Replacement

The ZF 8HP transmission made its debut in 2009, and since its introduction, has been one of the top choices for international car manufacturers. BMW, one of ZF’s largest customers, uses the 8HP across its entire product portfolio. BMWs featuring...

Read more...

The Ins And Outs Of Sanders

Sanders are required tools in today’s collision repair shop. Body techs and painters rely upon them every day to achieve that perfect finish on your customers’ vehicles. Whether you’re prepping a panel for paint or removing imperfections before...

Read more...

Are You Regularly Maintaining Your Equipment?

Technicians who are idling because the welder won’t feed wire, the hydraulic ram won’t pull chains, the booth heater won’t heat or the air compressor won’t compress enough air is a costly mistake, as labor time is the most expensive thing in any...

Read more...

Celebrate 'Back To The Future' Day By Watching The Time Machine Get A 2015 Detail

    For many today is just another Wednesday, but for a lot of people it is more than just your average Wednesday, it is "Back to the Future" Day. It is a day that everyone who watched the cult classic trilogy Back to the Future recognizes...

Read more...

Using Your Oscilloscope: Current Ramp Test Ignition Coils

Regardless of design configuration, the role of the ignition coil is to multiply battery voltage into high voltage. Following Ohm’s law for the conversion of volts to amperes, oil-filled coils generally require 3 to 5 amperes of primary current...

Read more...

Serial Data Bus Diagnostics

Understanding The Function of Serial Data Buses If serial data buses did not exist, a wiring harness would have to be five times its normal size and use twice as many sensors to deliver the same level of functionality and safety we see in the modern...

Read more...

Throttle-By-Wire Codes: P1512 On 2002 GMC Envoy

The PCM continuously monitors the commanded and actual throttle positions. The commanded throttle position is compared to the actual throttle position based on ­accelerator pedal position and possibly other limiting factors, and both values should...

Read more...
Home Brake Job Ford Fusion Brake Job, Rotors, Front Pads

Print Print Email Email

The Ford Fusion is based on the Ford CD3 platform that includes the Mercury Milan, Lincoln Zephyr and Mazda 6. Most of these vehicles went on sale as 2006 models. The platform was intended to be a replacement for the then discontinued Ford Taurus.

The brakes on these vehicles are straightforward and do not break any new ground. The brake systems on all variants have disc brakes at all corners. The parking brake is part of the rear caliper and has a straightforward adjustment. There are no major changes to the brakes system from 2006 to 2009. For the 2008 model year, ABS became a standard feature, as did a direct tire pressure monitoring system.


On a side note, the Fusion was originally to be called the Ford Futura, but Ford lost a trademark lawsuit to Pep Boys auto parts store, which has a line of tires under the Futura brand. American trademark law generally considers a name abandoned if the owner does not use it for three calendar years, and the long history of the name in the Ford line did not impress the court.

Rotors
Unfortunately, the rotors on the Fusion do not have too much material. It is difficult to get at least one turn out of the rotors before they are under spec. Overall runout and thickness variation should be less than 0.001.”

Front Rotors
New thickness: 25 mm (0.98”)
Min. thickness: 23 mm (0.91”)
Min. thickness to machine: 24.1 mm (0.94”)

Rear Rotors
New thickness: 10 mm (0.39”)
Min thickness: 8 mm (0.31”)
Min thickness to machine: 9.1 mm (0.35”)

Front Brake Pad Removal:
1. Push the caliper pistons back into the bores. Do not pry in the caliper sight holes to retract the pistons, as this can damage the caliper pistons and boots.

2. Remove the brake caliper bolts and position the caliper aside.

3. Remove the brake pad retraction springs from the holes.

4. Remove the brake pads, brake pad shims and stainless steel shims.

5. Inspect the brake pads and shims for wear or contamination. There should be at least 3 mm of material and the pads should not differ from side-to-side by more than 2 mm. The pads should not taper more than 2 mm.

6. Remove the brake pad slides.

Front Brake Pad Installation:
1. Protect the caliper piston and boots when pushing the caliper piston into the bores in order to install the new pads.

2. Install the brake pad slides.

3. Apply grease to the backing plate and shims in the areas indicated.

4. Install the brake pad shims and the caliper bracket slides. If you are using an OE-style shim, the cut shim is directional and used on the inboard pad only. The cut is positioned toward the leading side. Correct installation can be verified if the shim hole is positioned on the bottom side.

5. Install the new pads.

6. Install the brake pad retraction springs. New springs should be used. It has been shown the springs increase fuel mileage by 1 percent and decrease incidents of brake noise by 10 percent.

 

7. Position the brake caliper and install the bolts. Make sure that the caliper guide pin boots are fully seated or damage to the caliper guide pin boots can occur. Tighten to 37 ft.-lbs.

Rear Pad Brake Removal:
1. Disconnect the parking brake cable from the brake caliper.

2. Pull back the parking brake lever.

3. Disconnect the cable from the parking brake lever.

4. Remove the cable conduit-retaining clip.

5. Disconnect the cable from the brake caliper.

6. Retract the piston. Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and boots.

7. Remove the brake caliper bolts and position the caliper aside.

8. Remove the pads, shims and slide clips. Inspect the brake pads for wear or contamination.

9. Inspect the brake pads for wear and contamination. There should be at least 3 mm of material and the pads should not differ from side-to-side by more than 2 mm. The pads should not taper more than 2 mm.

10. Remove the brake caliper anchor plate bolts and the anchor plate.

Rear Brake Installation:
1. Install the brake caliper anchor plate and the two brake caliper anchor plate bolts. Tighten to 52 ft.-lbs.

2. Install the two brake pads and slide clips to the brake caliper anchor plate. Position the notch in the caliper piston so that it will correctly align with the pin on the backside of the inboard brake pad. Install the brake caliper.

3. Position the brake caliper on the anchor plate and install the bolts, tighten to 19 ft.-lbs.

4. Install the parking brake cable to the caliper.

5. Pull back the parking brake lever.

6. Connect the cable to the parking brake lever.

7. Install the cable conduit-retaining clip.

8. Cycle the park brake several times to verify normal operation.

9. Test for normal operation.

Parking Brake Adjustment:
1. Remove the access panel behind the center console. Do not pry at the floor console rear access panel with a screwdriver or damage to the panel may occur.

2. Note: The dimension will vary depending on the amount of cable stretch. New cables require cycling the parking brake control 5-10 times to remove the cable slack. Adjust the parking brake adjustment nut as shown below.

3. Verify correct operation of the parking brake system.

• At two clicks of the parking brake control, slight drag at the rear wheels should be present.

• At five clicks of the parking brake control, no movement at the wheels should be present.

Brake System Bleeding
Anti-Lock System Bleed

Bleeding the Hydraulic Control Unit (HCU) is required only when removing or installing the HCU, master cylinder or opening the lines to the HCU. A scan tool with the ability to interface with the HCU is required for bleeding.

Note: Carrying out the system bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws.

Note: Adequate voltage to the HCU module is required during the anti-lock portion of the system bleed.

1. Connect the diagnostic tool.

2. Access the system bleed function.

3. Manually bleed the brake hydraulic system.

4. Repeat the procedure carrying out a total of two diagnostic tool cycles and two manual bleed cycles.

Manual Bleed:

1. Fill the brake master cylinder reservoir with the specified brake fluid.

2. Begin bleeding the system, going in order from the right rear wheel, to the left rear wheel, to the right front wheel and ending with the left front wheel.

3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end in a container partially filled with clean brake fluid.

4. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal.

5. Loosen the bleeder screw until the fluid flow stops. Maintain pressure on the brake pedal and tighten the bleeder screw.

6. Repeat steps 3-5 until clear, bubble-free fluid flows.

7. Tighten the bleeder screw to 71 in.-lbs.

8. Refill the brake master cylinder reservoir as necessary.

9. Continue bleeding the brake hydraulic system at each wheel until a firm pedal is achieved.

Gravity Bleed:
1. Begin bleeding the system, going in order from the right rear wheel, to the left rear wheel, to the right front wheel and ending with the left front wheel.

2. Attach a rubber drain hose to the rear bleeder screw and submerge the free end in a container partially filled with clean brake fluid.

3. Loosen the bleeder screw and leave it open until clear, bubble-free brake fluid flows.

4. Tighten the bleeder screw to 71 in.-lbs.

5. Continue bleeding the system at each wheel.

TSB & Recalls:
There are no TSBs or recalls issued by Ford or Mazda for the brake system for this platform. But, there havr been two TSBs issued for the creaks and groans in the front suspension that the customer might perceive as brake noise.

TSB 08-18-4
Front Strut Noise


Vehicles:
2006-’09 Fusion, Zephyr, MKZ and Milan

Issue:

Some vehicles may exhibit a popping, rubbing, grunting, squeaking, crunching or creaking type noise from the front strut mount when going over bumps, while driving at 1-10 mph (1-16 Km/h) and/or during parking lot maneuvers. Typically, the noise is heard in the front outboard wheel while turning at low speeds.

The jounce bumper rubbing against the dry strut plate may cause this noise. Spraying the area with an aerosol lubricant will work only until the lubricant is washed away by road spray. The only way to get rid of the noise is to disassemble the strut and lubricate the pieces.

Action:
1. Remove front shock absorber and spring assembly.

2. Disassemble the shock absorber and spring assembly.

3. Apply only silicone brake grease around the upper and lower contact surfaces of the shock absorber piston bounce bumper. Do not use chassis grease as it will cause the rubber and plastic parts to deform.

4. Repeat the procedure on the other side of the vehicle.

TSB 06-24-7
Front Suspension Noise: Squeak/Creak Over Bumps or When Turning

Vehicles: 2006 Fusion, Zephyr and Milan

Issue: Some 2006 Fusion, Milan and Zephyr vehicles may exhibit a concern of a squeak or creak noise from the front suspension while going over bumps or turning. The noise is caused by corrosion and cracks in the lower control arm brackets.

Action:
1. To isolate the creak / squeak noise, place two chassis ears microphones on each side on the right front and left front, clip one mic to the side member at the front lower control arm pockets.

2. Take the vehicle for a short drive at low speeds.

3. If noise at sub-frame bracket exists, inspect the bracket area very closely for rust/cracks isolated to the area along the welds.

4. If there is rust under or along welds as indication of a cracked weld, the sub-frame may need to be welded or replaced. Also, Ford recommends treating the area with a corrosion resistant coating.

 

The following two tabs change content below.
Andrew Markel

Andrew Markel

Andrew Markel is the editor of Brake & Front End magazine. He has been with Babcox Media for 15 years. He is a technician and former service writer and holds several automotive certifications from ASE and ­aftermarket manufacturers. He can be reached at [email protected]
Andrew Markel

Latest posts by Andrew Markel (see all)

  • Scott

    So I did the breaks on my fiancé 2010 Ford Fusion and now I’m having a hard time to get them to bleed any suggestions ?

Latest articles from our other sites:

University Of The Aftermarket Foundation Introduces New Website

The University of the Aftermarket Foundation has launched a new website at UofAFoundation.com. The new site features the foundation’s mission, latest news and donor information. The new site also was...More

Bumper To Bumper Hosts The 'Bridge To Excellence Conference' In Little Rock, Arkansas

Bumper to Bumper recently hosted its 2016 Bridge to Excellence Conference in Little Rock, Arkansas. More than 500 people were in attendance, including 392 employees representing 163 stores from Crow-Burlingame,...More

Snap-on 18V Lithium Cordless Angle Grinder Features Safety Switch

The new Snap-on CTGR8855 18V Lithium Cordless Angle Grinder is the next step in grinders, similar to the CTGR8850, but features a unique safety switch that cuts off power if the tool is dropped. “We...More

Cut Jeep Exhaust Manifold Repairs Times with ProMAXX MYRA

ProMAXX Tool has announced the availability of a ProKit for the Jeep Grand Cherokee, Dodge Dakota and Dodge Durango. “Our Dodge 5.7L HEMI ProKit has been very successful in aiding technicians in...More

Spring A/C Repair Do's and Don'ts

As vehicle owners in many parts of the country begin using their air conditioning systems for the first time this year, some will be surprised to find their A/C system is not functioning properly or isn’t...More

Bumper To Bumper Hosts The 'Bridge To Excellence Conference' In Little Rock, Arkansas

Bumper to Bumper recently hosted its 2016 Bridge to Excellence Conference in Little Rock, Arkansas. More than 500 people were in attendance, including 392 employees representing 163 stores from Crow-Burlingame,...More