AfterMarketNews AfterMarketNews Auto Care Pro AutoCareCareerHub 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

Automotive Pet Peeves 2: Reader Feedback Is Overwhelming

How many auto repair pet peeves are out there? Well, enough of them that one article wouldn’t hold them all. I’ve received so many emails, texts and phone calls about my article in the February issue that I thought: why not put everyone’s pet peeve...


Air Filter Show & Tell: Seeing Is Believing

Air filters are normal wear items that ­require regular checks and ­replacement. Their role is to trap dirt particles that can cause damage to engine cylinders, walls, pistons and piston rings. In fuel-injected vehicles, the air filter also plays...


Searching For 'Black Holes': Job Totals Reveal Missed Selling Opportunities

The concept for Maintenance Chronicle is simple: We ask one shop to record their maintenance sales for a two-week period, and then we see what we learn from the results. This edition of Maintenance Chronicle also proved to be valuable for the shop we...


MAZDA: Timing Belt & Chain Replacement

This month, we’re going to be looking at the ­timing components on the Mazda line of vehicles. We’ll be focusing on timing belts since they are considered a service item and will present the greater amount of opportunity for replacement. Then, we’ll...


Honda Element Brake Job

It may look like a car that was never removed from the box it came in, but the Honda Element isn’t boxy when it comes to the brakes. Based on the CR-V platform, there is also nothing tricky when it comes to service. But, its brake system is hardware...


The Changing Maintenance Market: New Technologies Mean More Opportunities

Most of us wake up each morning, not ­realizing that our professional world has changed even as we slept. Our first job of the day is to service a ­vehicle equipped with an oil life monitor. Not only do we discover that modern oil life monitors can...


Maintaining Your Spray Guns

If there’s one piece of equipment that epitomizes the painter and the paint shop, it’s the spray gun. Over the years we’ve seen many spray guns. Although there are operating principles and functions that remain the same, some have been improved...


Wheel Bearing Adjustment Tools & Equipment

A recent survey showed that more than half of the bearings on the road today are adjusted incorrectly. A wheel bearing that’s out of adjustment can reduce bearing life and can affect more than just the bearing. An out-of-adjustment bearing affects...


ETI's ToolTech 2015 Focuses on the Connected Vehicle

ETI’s Annual ToolTech conference remains the premiere event in the tool and equipment industry with more than 115 professionals from over 50 companies in attendance at this year’s ToolTech 2015 in Austin, TX. The Equipment and Tool Institute's...


Diagnostic Dilemma: The Case of the Missing Code

When doing mobile diagnostic work, no-code stalling complaints are a major part of your agenda. In most cases, the client shop is simply too busy to duplicate the failure or, in some cases, a long test drive will yield nothing in the way of useful...


Secondary Ignition: The Art of Spark

What is a coil? From the beginning of the internal combustion engine, several different ignition systems have been used to create a high-energy spark. The most popular system, and the one that’s in use today, is a step-up coil. A coil is nothing...


Diagnosing Catalytic Converter Failure Symptoms

Although construction can vary according to engine application, the common three-way catalytic converter contains a reduction and oxidation stage. To create maximum surface area, each stage is generally a ­ceramic or stainless steel honeycomb substrate...


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.

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

2006-’09 Fusion, Zephyr, MKZ and Milan


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.

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.

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 is an ASE Certified Technician and former service writer, and he brings this practical knowledge to the Brake & Front End team as editor.
  • 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:

Snap-on Partners With CRKT And Ken Onion To Design The Rave, Exclusive Compact Pocket Knife

Perfect for everyday carry, yet tough enough for life in the shop, the new Snap-on Rave SEK60 series knives are an exclusive Ken Onion design. This compact, folding pocket knife features a 2.3-inch blade...More

Auto Care Association And ASE Recognize World Class Technicians

Of the more than 840,000 automotive technicians working in the United States, 17 outstanding individuals have qualified for the prestigious 2015 World Class Technician Award. The Auto Care Association...More

Tips For Spark Plug Removal

Removal or installation of spark plugs on modern vehicles requires extreme precision and care. Before removing a spark plug, check to see if it’s still working properly and whether the engine itself...More

Oil Service for Today’s Vehicles

You have most likely been made aware over the last few years that you need to be diligent in which oil you choose when servicing today’s modern vehicles. Hopefully your team is trained to look up the...More

Deluxe Maintenance Carts from Homak

Homak Manufacturing’s Big Dawg series includes its 44" 10-drawer Deluxe Maintenance Carts. Built to handle the demands of professional shops, these carts feature thick-gauge steel frames, heavy-duty...More

K-Seal by Solv-Tec Offers One-Step Permanent Coolant Leak Repair

The company calls it 'The Miracle in the Little Blue Bottle' – K-Seal by Solv-Tec is a one-step permanent coolant leak repair that permanently seals most leaks in the engine block, cylinder head, head...More

Ultimate Underhood: From Mechanical Fuel Injection to Putters

Mechanical constant stream fuel injection is the pinnacle of pure mechanical engineering. The mechanic setting up the system must optimize the amount of fuel for a given throttle position, rpm and engine...More

Induction Cleaning Service For Direct-Injection Vehicles

You may have seen it before: misfire codes, stumbling and suspicious fuel trim numbers. On a scan tool, the engine may show a loss in volumetric efficiency. The driver may complain about a loss of power,...More