Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSFORD2007FUSION SEL, 2.3 Z, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 539 (BRAKE SYSTEM - GENERAL INFORMATION)DIAGNOSIS AND TESTINGBRAKE SYSTEMSYMPTOM TABLE

2007 Ford Fusion SEL, 2.3 Z, Standard

Symptom Table

2007 Ford Fusion SEL, 2.3 Z, StandardSECTION Symptom Table

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

SYMPTOM TABLE

Condition	Possible Sources	Action
The red brake warning indicator is always on	Brake fluid level	FILL the brake master cylinder reservoir to the MAX line
	Parking brake	Make sure the parking brake is fully released
	Circuitry	CARRY OUT CAN diagnostics.
	Controller area network (CAN) communication system	GO to PINPOINT TEST A .
	Instrument cluster
	Smart junction box (SJB)
The red brake warning indicator is inoperative	Circuitry	REFER to INSTRUMENT CLUSTER .
	Instrument cluster
	Missing controller area network (CAN) communication
The brakes pull or drift	Tire air pressure	CHECK the tires for uneven or excessive wear, and correct inflation
	Brake pads or shoes Brake components	CHECK the brake pads and shoes for uneven taper or excessive wear. REPAIR as necessary.
	Brake pads or shoes Brake components	CHECK the brake discs and drums and the hubs for damage. REPAIR as necessary.
	Suspension component Wheel alignment	CHECK wheel alignment. REFER to SUSPENSION SYSTEM-GENERAL INFORMATION .
Brake pedal goes down fast	Brake fluid level	INSPECT the system for leaks. FILL the brake master cylinder reservoir. BLEED the system. REFER to BRAKE SYSTEM BLEEDING .
	Air in the system	INSPECT the system for leaks. BLEED the system. REFER to BRAKE SYSTEM BLEEDING .
	Brake master cylinder	CARRY OUT the BRAKE MASTER CYLINDER .
The brake pedal eases down slowly	Air in the system	INSPECT the system for leaks. BLEED the system. REFER to BRAKE SYSTEM BLEEDING .
The brake pedal eases down slowly	Brake master cylinder	CARRY OUT the BRAKE MASTER CYLINDER .
Brake lockup under light brake pedal force	Brake pads and shoes	CHECK the brake pads and shoes for uneven taper or excessive wear. REPAIR as necessary.
	Brake component	CHECK the brake components for correct operation. REPAIR as necessary.
	Parking brake component	REPAIR or INSTALL new components as necessary. REFER to PARKING BRAKE & ACTUATION .
	Anti-lock brake control system	CHECK the anti-lock brake control system. REFER to ANTI-LOCK BRAKE SYSTEM (ABS) MODULE .
Excessive/erratic brake pedal travel	Leak in the hydraulic system Air in the system Disc brake caliper(s) or wheel cylinder(s)	INSPECT the system for leaks. BLEED the system. REFER to BRAKE SYSTEM BLEEDING .
	Brake master cylinder	CARRY OUT the BRAKE MASTER CYLINDER .
	Brake pads	CHECK the brake pads for excessive wear.
	Brake pedal	CHECK the brake pedal for binding or obstructions. REPAIR as necessary.
Brakes drag	Parking brake component	REPAIR or INSTALL new components as necessary. REFER to PARKING BRAKE & ACTUATION .
	Brake caliper guide pins	CHECK the caliper guide pins for correct operation. INSTALL new components as necessary. REFER to BRAKE CALIPER GUIDE PINS .
	Disc brake caliper(s)	REPAIR or INSTALL new brake calipers as necessary. REFER to BRAKE CALIPER for front disc brakes or BRAKE CALIPER for rear disc brakes.
	Brake booster	CARRY OUT the BRAKE BOOSTER .
	Brake master cylinder	CARRY OUT the BRAKE MASTER CYLINDER .
Excessive brake pedal effort	Brake booster	CARRY OUT the BRAKE BOOSTER .
	Brake booster check valve	CARRY OUT the CHECK VALVE .
	Brake booster manifold vacuum hose	REROUTE, REPAIR or INSTALL new components as necessary.
Vibration when the brakes are applied	Uneven brake pad wear Brake disc pad transfer Uneven brake disc wear Suspension components	COMPLETE the brake system inspection described in INSPECTION AND VERIFICATION . GO to PINPOINT TEST B .
Brake vibration/shudder - occurs when the brake pedal is released	Brake caliper guide pins	INSPECT the brake caliper guide pins for correct operation. REFER to BRAKE CALIPER GUIDE PINS .
	Brake drag	INSPECT the brake pads for premature wear. REPAIR or INSTALL a new caliper or brake caliper anchor plate as necessary. REFER to BRAKE CALIPER or BRAKE CALIPER ANCHOR PLATE for front disc brakes or BRAKE CALIPER for rear disc brakes.
Adjustable brake pedal is inoperative/does not operate correctly - memory	Fuse Circuitry Memory set switch Adjustable pedal switch Adjustable pedal potentiometer Adjustable pedal motor Driver seat module (DSM)	GO to PINPOINT TEST C .
Rattling noise	Caliper mounting bolts loose	CHECK the caliper bolts. TIGHTEN to specifications. REFER to BRAKE CALIPER for front disc brakes or BRAKE CALIPER for rear disc brakes.
	Damaged or worn caliper guide pins or retainers	CHECK the caliper guide pins and retainers for correct operation. INSTALL new components as necessary. REFER to BRAKE CALIPER GUIDE PINS .
	Missing or damaged anti-rattle clips or springs	CHECK the brake pads for missing clips or broken springs. INSTALL new components as necessary. REFER to BRAKE PADS for front disc brakes or BRAKE PADS for rear disc brakes.
	Loose brake disc shield	TIGHTEN the brake disc shield bolts to specification. REFER to BRAKE DISC SHIELD for front disc brakes or BRAKE DISC SHIELD for rear disc brakes.
Clicking noise - with brakes applied with anti-lock brake system (ABS) brakes	ABS hydraulic control unit	Acceptable condition.
Squealing noise - occurs on first (morning) brake application	Brake pads	Acceptable condition. Caused by humidity and low brake pad temperature.
Squealing noise - a continuous squeal	Brake pads worn below minimum thickness	INSPECT brake pads for excessive wear, taper wear or uneven wear. VERIFY brake pads are within minimum specifications. REFER to BRAKE PADS .
Squealing noise - an intermittent squeal brought on by cold, heat, water, mud or snow	Brake pads	Acceptable condition.
Groaning noise - occurs at low speeds with brake lightly applied (creeping)	Brake pads	Acceptable condition.
Grinding noise - continuous	Brake pads worn below minimum thickness	INSPECT the brake pads, brake discs, and attaching hardware for damage. VERIFY brake components are within specifications. REFER to SPECIFICATIONS .
Moaning noise	Brake pads contaminated with grease or oil	INSPECT the brake pads for contamination. REPAIR or INSTALL new components as necessary. REFER to BRAKE PADS for front disc brakes or BRAKE PADS for rear disc brakes.

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.