Buy Ford Fusion Disc Brake Pad Sets

Disc brake pads-sometimes called friction pads, disc linings, or stopping pads-are the parts your Ford Fusion's calipers squeeze against the brake rotors to slow the car. Every 2006-2020 Fusion (gas, Hybrid, and Energi) uses a four-pad "set" per axle that wears down with use. Choosing the right material (ceramic, semi-metallic, or organic), replacing pads before they reach the 3 mm service limit, and following a proper break-in routine keeps stopping distances short, reduces brake dust, and helps the pads last tens of thousands of miles. Modern rules are driving all pads to be nearly copper-free by 2025 to protect waterways. For full details, Ford's Owner's Manual, the U.S. National Highway Traffic Safety Administration site, and the EPA's Copper-Free Brake Initiative provide helpful background. (Wikipedia, Wikipedia, NHTSA)

Brake pads turn the car's motion into heat by pressing their friction faces against the spinning rotor, bringing the wheel to a stop. When you hit the pedal, hydraulic pressure forces the caliper pistons out, clamping the pads onto the rotor's face. (Wikipedia, Wikipedia)

• Model years: Two Fusion generations ran from 2006 to 2020; all U.S. trims use four-wheel disc brakes. (Wikipedia)
• Hybrid advantage: Hybrids regenerate energy first, so their friction pads often last longer than on non-hybrids. (Reddit)
• Front vs. rear: Front pads handle most braking force, so they usually wear faster than rear pads. (Wikipedia)

• Ceramic: Quiet, light dust, steady feel in normal driving, but higher cost. (Bridgestone Tires)
• Semi-metallic: Great cold bite and heat handling, yet a bit noisier and dustier. (Car and Driver)
• Organic/NAO: Soft, low-cost, but shorter life and more fade under heavy loads.

For deeper reading, see this .

• Squeal tabs: Little metal "squealers" rub the rotor and whistle when only about 3 mm of pad remains. (Chapel Hill Tire)
• Grinding or vibration: Means friction material is gone or uneven deposits are on the rotor. (Wikipedia)
• Longer stops or soft pedal: Pad or rotor thickness may be below spec. (Ford Service Content)

Ford's maintenance schedule calls for brake inspections every 10,000 miles or 12 months and replacement when pad lining is under 3 mm. (richmondfordwest.com, Ford Service Content)

When shopping, match pad material to driving style and climate, look for "copper-free" or "low-copper" labels (≤0.5 % by 2025), and be sure the set includes new abutment clips and shims. (US EPA, Department of Toxic Substances Control)

1. Loosen lug nuts, then lift and secure the car.
2. Remove caliper bolts (rear bracket bolts often torque to ~60 ft-lb). (Reddit)
3. Compress pistons with a C-clamp or screw-tool.
4. Clean & grease slider pins and pad ears.
5. Torque wheel nuts to 100 ft-lb afterward and re-check after 100 miles. (Ford Service Content)

Full instructions are in the 2019 Fusion Owner's Manual.

A proper "bed-in" (or burnish) procedure deposits an even pad layer on the rotor: perform 4-6 medium stops from 45 mph down to 10 mph, then 2 firm stops from 55 mph, letting brakes cool between runs. Detailed science is in StopTech's bed-in whitepaper.

Work on a cool, level surface, chock wheels, wear eye protection, and never open the master-cylinder cap longer than needed to avoid moisture. ABS and stability-control still rely on healthy pads; see NHTSA's brake tech page for more tips. (NHTSA)

• Dust buildup: Some pad mixes shed more particles; recent studies show brake dust can rival diesel soot for toxicity. (The Guardian, UC Irvine News)
• Squeal after install: Often fixed by re-bedding or adding high-temp shim grease. (centricparts.com)
• Pulsation: Warped rotors or uneven pad transfer; resurface or replace rotors in pairs. (Ford Service Content)

Each brake job may also need rotors, caliper guide pins, hardware clips, brake fluid, and wheel hub fasteners. Pads and discs work together as a system; worn rotors cut new pads short. (Wikipedia, Wikipedia)

California's law and a nationwide voluntary pact push copper in pads toward near-zero by January 1 2025, protecting streams from metal runoff. (US EPA, Department of Toxic Substances Control, EHN)

Brake dust also contributes fine particles that can harm lungs; see this Guardian report for details.

A full front-or-rear pad set for a Fusion typically costs $35-$90 USD, depending on material and included hardware, plus shop labor if you choose professional service. (Prices vary by region.)

Q: What does a disc brake pad set do?
A: It supplies the friction that stops the wheels when the caliper squeezes the pads against the rotor. (Wikipedia)

Q: Which Fusion years use the same pads?
A: All 2006-2020 North-American Fusions share the same basic pad shape per axle within each generation; always confirm by engine size and caliper option. (Wikipedia)

Q: How long do factory pads last?
A: Many drivers see 30,000-60,000 miles; hybrids often double that thanks to regenerative braking. (Reddit)

Q: What's the minimum pad thickness?
A: Replace when friction material is 3 mm (about ⅛-inch) or less. (Ford Service Content)

Q: Why do my brakes squeak?
A: Wear-indicator tabs scrape the rotor once pads get thin, warning you to replace them. (Chapel Hill Tire)

Q: Can I mix ceramic fronts with metallic rears?
A: Mixing materials can change pedal feel and balance; use the same compound per axle for best results. (Bridgestone Tires)

Q: Do hybrids need pad changes?
A: Yes-regeneration slows wear but doesn't eliminate it; inspect yearly. (Reddit)

Q: What torque for caliper bracket bolts?
A: About 60 ft-lb on many models; always verify your exact spec. (Reddit)

Q: How do I bed new pads?
A: Perform a series of controlled stops as outlined in the StopTech procedure. (centricparts.com)

Q: Must I replace rotors too?
A: Rotors below minimum thickness or with deep grooves should be replaced or resurfaced with each pad change. (Ford Service Content)

Q: Are copper-free pads required?
A: Laws lower copper to 0.5 % in 2025, so most new pads are already copper-free. (US EPA)

Q: Are ceramic pads better for dust?
A: Yes, ceramics usually shed less visible dust than metallic pads. (Bridgestone Tires)

Q: Is brake dust harmful?
A: Studies show certain brake dust particles can irritate lungs; wearing a mask while cleaning wheels is smart. (The Guardian)

Q: Can I recycle old pads?
A: Many towns treat used pads as hazardous waste-check local rules for drop-off centers. (EPA NERL)

Q: What basic tools do I need?
A: Jack stands, lug wrench, socket set, C-clamp, brake cleaner, and torque wrench. (Ford Service Content)

Q: Will changing pads affect ABS?
A: No, but dirty sensors or low fluid after service can trigger a warning light. (NHTSA)

Q: Do front and rear pads differ?
A: Yes; front pads are larger and made for heavier braking loads. (Wikipedia)

Q: How heavy is a pad set?
A: A full axle set (four pads) weighs about 3-5 lb, varying by material. (Car and Driver)

Q: Do I need to bleed brakes after a pad swap?
A: Not if you only compress the pistons carefully and don't open the system; top off fluid as needed. (Ford Service Content)

For deeper technical insights, explore the links embedded above and keep your Fusion's brakes in top shape!