Doing brakes on a Ford Fusion is pretty straightforward, but if you want to do it right (and safe), you'll need the exact tools and sizes. This guide walks you through replacing front brake pads and rotors on a 2013 to 2020 Ford Fusion, with every socket and tool size you actually need—no guesswork.
- Using wrong tools can damage caliper pins
- Improper torque causes uneven wear
- Never work under a car supported only by a jack
🔧 Tools & Socket Sizes You'll Need
| Part | Tool/Socket Size | Notes |
|---|---|---|
| Wheel Lug Nuts | 19mm Deep Socket | Impact or breaker bar ready |
| Caliper Slide Pins | 7mm Allen Wrench | Not a bolt—Allen key style |
| Caliper Bracket Bolts | 18mm Socket | Larger bolts, use breaker if needed |
| Other Essentials | — | Pry bar, brake grease, wire brush, brake cleaner |
🛑 Step-by-Step: Front Brake Job on a Ford Fusion (2013–2020)
1. Break the Lug Nuts Loose
Use a 19mm deep socket and either a breaker bar or impact to break all lug nuts loose. Don't remove them yet.
Proper technique for breaking loose lug nuts with 19mm socket
2. Jack Up the Car & Secure It
Jack from the factory jack point and place jack stands under the pinch weld or frame. Never work with just the jack holding the car.
3. Remove the Wheel
Finish removing the lug nuts and pull the wheel off to expose the brake components.
4. Remove the Caliper (7mm Allen)
Use a 7mm Allen wrench to remove the two caliper slide pins. Wiggle and slide the caliper off gently. Hang it with a bungee or wire—never let it hang by the brake hose.
Locating the 7mm Allen-head caliper slide pins (circled in red)
5. Remove the Caliper Bracket (18mm)
Now use your 18mm socket to remove the caliper bracket bolts. These bolts can be tight—use a breaker bar or impact if needed.
6. Remove the Rotor
If the rotor is rusted on, tap around the hat with a mallet or use a pry bar carefully. No set screw on most Fusions.
7. Prep the New Parts
- Use brake cleaner to clean the new rotors
- Wire brush the caliper bracket and pad contact points
- Apply brake grease to slider pins and pad ears
8. Reinstall Everything
- Put the new rotor on the hub
- Bolt the bracket back on (18mm, torque ~85-100 ft-lbs)
- Insert the new pads
- Compress the caliper piston with a C-clamp or caliper tool
- Slide the caliper back over pads
- Reinstall 7mm Allen bolts (torque ~25-40 ft-lbs)
9. Reinstall the Wheel
Put the wheel back on and hand-tighten the lug nuts.
10. Lower the Car & Torque the Wheels
Lower the vehicle and torque the 19mm lug nuts to 100 ft-lbs in a criss-cross pattern.
11. Pump the Brakes Before Driving
Before starting the car, pump the brake pedal until it firms up. This seats the pistons against the new pads.
🔧 Quick Pro Tips
- Do both sides—even if one looks worse, change both pads/rotors together
- Clean slide pins and make sure they move freely
- If your brake pedal feels soft after, it may be time to bleed the system
👨🏾🔧 Don't Want to Do It Yourself?
If this looks like a lot—or you just don't want to deal with it—I'll come to your driveway or parking lot and do the job for you, professionally and fast.
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