AfterMarketNews Auto Care Pro AutoProJobs Auto-Video.com Brake&Frontend BodyShopBusiness Counterman EngineBuilder Fleet Equipment ImportCar Motorcycle & Powersports News Servicio Automotriz Shop Owner Tire Review Tech Shop Tomorrow's Tech Underhood Service

No More Free Tire ­Rotations!

Tire rotation is a cornerstone of vehicle preventive maintenance and tire longevity. It is a well-proven fact that tire tread life can be greatly enhanced by regular and timely tire rotation. During rotation, each tire and wheel is ­removed from...

Read more...

ASE G1: How To Measure Cold Cranking Amps, Reserve Capacity

The ASE G1 test contains 55 scored, job-related questions, 15% of which will concern electrical maintenance and repairs. From the ASE G1 study guide, you will need to know how to: • Perform battery tests (load and capacitance); ­determine needed...

Read more...

ASE A5: Brake Fluid And Bleeding Sequence

The ASE A5 Test includes a portion on brake fluid, bleeding, flushing and leak testing. You must know how to: • Diagnose poor stopping, pulling, dragging, or incorrect pedal travel caused by problems in the brake fluid; determine needed repairs. •...

Read more...

When Timing Is Everything: A Look At The 2.5L, 2.0L Powerplants

Last month, we looked at the timing chain setup on the Audi 3.2L engine and saw how a lack of oil changes can adversely affect the tensioners and cause engine failure. We’ve also seen similar issues with the timing chain setups on the 2.5L 5-cylinder...

Read more...

Modern Charging Systems: Cover All The Bases During the Diagnostic Process

To quote a familiar situation: “My customer’s car is now on its third alternator in six months and my jobber store refuses to ­warranty a fourth.” In other words, the parts supplier believes that an underlying problem is causing these alternators...

Read more...

Audi Fuel System: MIL On/Multiple Low Fuel Pressure DTCs

Due to fuel intrusion into the low-pressure ­system fuel pressure sensor (G410), a false signal may be sent to the controller, resulting in a reading that is out of tolerance. Model: 2007 Audi A4 Sedan V6-3.2L Scenario: The MIL is on and one or...

Read more...

Redline Detection Seeks Nominations for 2nd Annual Redline Rock Star Performance Award

Redline Detection is encouraging anyone who works with, or knows, a talented technician to nominate him or her for the second annual Redline Rock Star Performance Award. The award recognizes a technician for their commitment to family, community and...

Read more...

Automotive Lift Institute (ALI) Elects 2015 Board

Jerome Lentz of Challenger Lifts (Louisville, Ky.) has been elected chairman of the Automotive Lift Institute (ALI) Board of Directors for 2015. Voting took place at ALI’s annual membership meeting Nov. 3 in Las Vegas. Lentz’s 2015 term will be...

Read more...

Top 5 Tools: John Forro, AST, Automotive Service Technology in Hinckley, OH

John Forro AST, Automotive Service Technology Hinckley, OH ALLDATA Information System: I use this system daily for researching labor pricing, wiring schematics, circuit descriptions, torque specs, etc. One doesn’t need to memorize all the information...

Read more...

Must-Read TPMS Technical Service Bulletins

Here’s a rundown of the top technical service bulletins related to TPMS. These TSBs should be analyzed by every technician that services TPMS. Audi TSB Number: 4413382034445/1 Models: 2010-’14 A4/S4, A5/S5 and Q5 Summary: This TSB addresses TPMS...

Read more...

Ford Reflash: Setting Up Your PC

You’ve just finished up a job on a Ford vehicle, and you’re about to try and start it up. However, it needs programmed first. You’ve decided to use a J2534 tool, but there are certain things you’ll need to consider ­before purchasing that subscription...

Read more...

Fuel Line Replacement: The Why and How

If you live in a state that doesn’t get snow, you can stop reading right now. If you live in the Snow Belt, you are about a month away from snow and ice. It’s not the adverse driving conditions that should scare you or your customers, it’s...

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

Latest posts by Andrew Markel (see all)

Latest articles from our other sites:

Redline Detection Seeks Nominations for 2nd Annual Redline Rock Star Performance Award

Redline Detection is encouraging anyone who works with, or knows, a talented technician to nominate him or her for the second annual Redline Rock Star Performance Award. The award recognizes a technician...More

Hunter’s Quick Tread Produces Fast, Accurate Tread Depth Readings

Hunter Engineering Company announces its new Quick Tread drive-over tread depth system, which uses point cloud technology to automatically measure the tread depth of each tire without a time loss....More

When Timing Is Everything: A Look At The 2.5L, 2.0L Powerplants

Last month, we looked at the timing chain setup on the Audi 3.2L engine and saw how a lack of oil changes can adversely affect the tensioners and cause engine failure. We’ve also seen similar issues...More

Modern Charging Systems: Cover All The Bases During the Diagnostic Process

To quote a familiar situation: “My customer’s car is now on its third alternator in six months and my jobber store refuses to ­warranty a fourth.” In other words, the parts supplier believes...More

Redline Detection Seeks Nominations for 2nd Annual Redline Rock Star Performance Award

Redline Detection is encouraging anyone who works with, or knows, a talented technician to nominate him or her for the second annual Redline Rock Star Performance Award. The award recognizes a technician...More

Hunter’s Quick Tread Produces Fast, Accurate Tread Depth Readings

Hunter Engineering Company announces its new Quick Tread drive-over tread depth system, which uses point cloud technology to automatically measure the tread depth of each tire without a time loss....More

Inspection TIps For Chain-Driven Water Pumps

Automakers are always trying to remove items from the accessory drive belt. This improves the efficiency of the engine and can extend the life of the belt. But where do you put the water pump? Some...More

Must-Read TPMS Technical Service Bulletins

Here’s a rundown of the top technical service bulletins related to TPMS. These TSBs should be analyzed by every technician that services TPMS. Audi TSB Number: 4413382034445/1 Models: 2010-’14 A4/S4,...More