Ford Fusion: Front Disc Brake / Brake Pads. Removal and Installation

Materials

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Remove the wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Remove and discard the brake caliper spring.
   

1. NOTICE: Do not pry in the caliper sight hole to retract the pistons as this can damage the pistons and boots.

   NOTICE: Do not allow the brake caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur.

   Remove the covers, the guide pins and position the brake caliper aside.
   Torque: 22 lb.ft (30 Nm)

1. NOTICE: Brake pads with adhesive on the insulator are one-time use only. When the brake pads are separated from the brake caliper, new brake pads must be installed to prevent brake noise and shudder.

   Separate the outboard brake pad from the brake caliper. Discard the brake pad.
   

1. NOTICE: Protect the caliper pistons and boots when pushing the caliper piston into the caliper piston bores or damage to components may occur.

   Use a C-clamp and a worn brake pad to compress the disc brake caliper pistons into the brake caliper bore.
   

1. NOTICE: Brake pads with adhesive on the insulator are one-time use only. When the brake pads are separated from the brake caliper, new brake pads must be installed to prevent brake noise and shudder.

   Remove and discard the inboard brake pad.
   

Installation

1. Clean the brake pad-to-anchor plate contact surfaces .
   

1. Clean all residual pad adhesive from the finger area of the brake caliper.
   Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

1. NOTICE: Brake pads with adhesive on the insulator are one-time use only. When the brake pads are separated from the brake caliper, new brake pads must be installed to prevent brake noise and shudder.

   NOTICE: Once the foil backing is removed from the brake pads do not touch the adhesive on the backing.

   NOTE: Make sure to apply the grease supplied with the brake pad kit to the brake pad-to-anchor plate contact points.

   Remove the foil backing and install the new brake pads.
   

1. NOTICE: Make sure that the brake hose is not twisted when installing the brake caliper or damage to the brake flexible hose may occur.

   Position the brake caliper and install the guide pins and covers.
   Torque: 41 lb.ft (55 Nm)

1. Install the new brake caliper spring.
   

1. Install the wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Depress the brake pedal several times, check the brake fluid level in the brake fluid reservoir and add the specified brake fluid as necessary.
   Material: Motorcraft® DOT 4 LV High Performance Motor Vehicle Brake Fluid / PM-20 (WSS-M6C65-A2)