🔧 Fusion - Front Strut Replacement

This procedure replaces both front struts using complete, preassembled strut units. A complete strut includes the coil spring, upper mount, bearing, and shock absorber, making the job safer for a first-time DIYer.

Difficulty Level: Intermediate | Estimated Time: 3-5 hours

Assumption: These instructions cover complete front strut assemblies, not rebuilding the original struts.

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⚠️ Safety & Precautions

• ⚠️ Replace front struts in pairs so handling and braking remain balanced.
• ⚠️ Never work beneath your Fusion while it is supported only by a floor jack.
• ⚠️ The coil spring stores enough energy to cause severe injury. Do not loosen the large center nut on the upper strut mount.
• ⚠️ Use complete preassembled struts. Rebuilding a strut requires a professional-quality spring compressor and advanced experience.
• ⚠️ Support the steering knuckle so the brake hose and wheel-speed sensor wire are not stretched.
• ⚠️ Keep grease and penetrating oil away from the brake rotor and pads.
• 🔋 Battery disconnection is not required.

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🔧 Required Tools

You'll need the following tools for this repair:

• Hydraulic floor jack rated 2-ton minimum
• Jack stands rated 2-ton minimum
• Wheel chocks
• 1/2-inch-drive breaker bar
• 1/2-inch-drive torque wrench rated to 250 Nm
• 3/8-inch-drive ratchet
• 13mm deep socket
• 15mm deep socket
• 18mm socket
• 21mm socket
• 24mm socket
• 18mm combination wrench
• 21mm combination wrench
• 24mm combination wrench
• 5mm hex-bit socket
• 6-inch socket extension
• 12-inch pry bar
• 16-ounce ball-peen hammer
• Brass drift punch
• Wire brush
• Paint marker
• Mechanic’s support wire rated 45kg minimum
• Safety glasses
• Mechanic’s gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Complete front strut assembly - Qty: 2 - Replace in pairs
• Front strut-to-steering-knuckle bolt and nut set - Qty: 2 sets
• Front stabilizer-bar link nut - Qty: 2
• Front strut upper-mount nut set - Qty: 2 sets
• Penetrating oil - Qty: 1 can

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📋 Before You Begin

• 🅿️ Park your Fusion on solid, level ground. Shift to Park and apply the parking brake.
• Place wheel chocks firmly behind both rear tires.
• Confirm the replacement struts are marked for the correct left and right sides.
• Arrange a professional four-wheel alignment immediately after replacement.
• No infotainment service mode or scan-tool command is required.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the Front Wheel Nuts

• Use a 21mm socket and 1/2-inch-drive breaker bar to loosen each front wheel nut approximately one-quarter turn.
• Do not remove the wheel nuts while the tires are supporting the vehicle.

Step 2: Raise and Support the Front

• Use the hydraulic floor jack beneath the specified front-center lifting point to raise your Fusion.
• Position both jack stands beneath the reinforced front side support points.
• Lower the vehicle onto the jack stands. Gently push the body to confirm it is stable.
• Keep the floor jack lightly touching the lifting point as a backup.

Step 3: Remove Both Front Wheels

• Use the 21mm socket and 1/2-inch-drive breaker bar to remove the wheel nuts.
• Lift off both wheels and place them flat away from the work area.

Step 4: Inspect and Mark the Original Position

• Use the wire brush to clean the strut-to-knuckle fasteners and stabilizer-link nut.
• Apply penetrating oil to the exposed fastener threads.
• Use the paint marker to trace the original relationship between the strut bracket and steering knuckle. This helps preserve approximate camber until alignment.
• Camber is the wheel’s inward or outward tilt when viewed from the front.

Step 5: Release the Brake Hose and Sensor Wire

• Use the 12-inch pry bar carefully to release the brake-hose retaining clip from the strut bracket.
• Release the wheel-speed sensor wire from its strut retainers by hand.
• Do not pull, twist, or hang the steering knuckle by either line.

Step 6: Disconnect the Stabilizer-Bar Link

• Use the 15mm deep socket and 3/8-inch-drive ratchet to loosen the stabilizer-link nut at the strut.
• If the stud spins, hold its center with the 5mm hex-bit socket while turning the nut with the 15mm combination wrench.
• Move the link away from the strut bracket without bending it.

Step 7: Support the Steering Knuckle

• Use mechanic’s support wire to suspend the steering knuckle from a solid body or subframe point.
• Leave enough movement to separate the knuckle from the strut, but do not place tension on the brake hose.

Step 8: Remove the Strut-to-Knuckle Fasteners

• Use the 24mm socket with the breaker bar and the 24mm combination wrench to loosen the two strut-to-knuckle fasteners.
• Remove the nuts, then use the brass drift punch and 16-ounce ball-peen hammer to drive the bolts out without damaging their threads.
• Hold the steering knuckle while separating it from the strut bracket.
• Do not allow the knuckle to pull outward far enough to separate the inner CV joint.

Step 9: Remove the Upper Strut-Mount Nuts

• Support the strut with one hand from inside the wheel opening.
• Under the hood, use the 13mm deep socket, 6-inch extension, and 3/8-inch-drive ratchet to remove the three small upper-mount nuts.
• Do not loosen the large center nut. It retains the compressed coil spring.
• Guide the complete strut assembly down and out through the wheel opening.

Step 10: Compare and Position the New Strut

• Place the old and new assemblies side by side and confirm the spring, brackets, mounting studs, and left/right orientation match.
• Use both hands to guide the new complete strut through the wheel opening and insert its upper studs into the body holes.
• Install the new upper-mount nuts finger-tight so the strut can still move slightly.
• Never rotate the center strut nut.

Step 11: Attach the Strut to the Steering Knuckle

• Use the 12-inch pry bar only as needed to align the steering knuckle with the strut bracket.
• Insert the new strut-to-knuckle bolts in their original direction and install the new nuts.
• Use the 24mm socket, 24mm combination wrench, and torque wrench to tighten both fasteners to 250 Nm (184 ft-lbs).

Step 12: Tighten the Upper Mount

• Use the 13mm deep socket, 6-inch extension, and torque wrench to tighten the three upper-mount nuts evenly to 35 Nm (26 ft-lbs).
• Do not use an impact wrench on the upper mount.

Step 13: Reconnect the Stabilizer-Bar Link

• Insert the stabilizer-link stud through the new strut bracket and install a new nut.
• Use the 15mm deep socket and torque wrench to tighten the nut to 80 Nm (59 ft-lbs).
• If the stud spins before the nut seats, use the 5mm hex-bit socket with the 15mm combination wrench, then finish with the torque wrench.

Step 14: Reattach the Hose and Sensor Wire

• Press the brake hose and wheel-speed sensor wire into the correct strut retainers by hand.
• Use the 12-inch pry bar gently if the metal brake-hose clip requires seating.
• Turn the steering knuckle fully in both directions by hand and verify neither line stretches, rubs, or twists.

Step 15: Replace the Strut on the Other Side

• Repeat Steps 4 through 14 on the opposite side using the same listed tools.
• Keep left- and right-side replacement struts on their designated sides.

Step 16: Reinstall the Wheels

• Install each wheel and start all wheel nuts by hand to prevent crossed threads.
• Use the 21mm socket and 1/2-inch-drive ratchet to snug the nuts in a star pattern.
• Use the hydraulic floor jack to raise your Fusion, remove the jack stands, and lower the tires until they firmly contact the ground.
• Use the 21mm socket and torque wrench to tighten the wheel nuts in a star pattern to 135 Nm (100 ft-lbs).

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✅ After Repair

• ✅ Bounce each front corner once and listen for clunks or movement.
• Start the engine and slowly turn the steering wheel from lock to lock. Stop if a hose, wire, or spring binds.
• Take a slow test drive on a quiet road. Check steering response, noises, and whether your Fusion pulls to one side.
• Obtain a professional four-wheel alignment before normal driving. Strut removal changes front-wheel alignment.
• After 80-160 km, use the 21mm socket and torque wrench to recheck wheel-nut torque at 135 Nm (100 ft-lbs).
• If the ABS, stability-control, or steering warning light appears, stop and inspect the wheel-speed sensor wiring before continuing.

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💰 DIY vs Shop Cost

Shop Cost: ₹45,000-₹85,000, approximately $540-$1,020, including parts, labor, and alignment

DIY Cost: ₹24,000-₹48,000, approximately $290-$575, for parts and alignment

You Save: ₹21,000-₹37,000, approximately $250-$445, by doing it yourself!

Local labor and imported-part prices vary. This repair takes a shop approximately 2.5-4 hours.

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🎯 Ready to get started?

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