I have a Ford Fusion that had a rf caliper that locked up. We replaced front calipers and hoses and bled the front brakes. The brake pedal would only pump up to half way no matter how much we bled them. I went ahead and drove it hoping something would free up. No change. Decided to bleed back brakes as well even though we had done no work in the rear. Found very little flow of fluid at rr and that wheel would not hold when pedal was applied. The other 3 wheels did.

We replaced the rr caliper and hose. Tried to bleed brakes again including abs bleed. Still little flow at rr. We replaced master cylinder. Bench bled master before install. Now we have NO brake pedal! NO wheels hold when pedal is applied (to the floor). Thought maybe master cylinder problem and replaced again. No luck!

I'm afraid my next step is a new or used abs unit but it didn't become an issue until the other work was done. Any suggestions on a cure?

 

You may need to pressure bleed it to make sure there's no air in the system.

 

CHIPJEEP
First off most people don't know to bench bleed the master cylinder.
Tou should bleed rr first then lr. Then move to the front right then to left.
You're going to have to bleed the ABS module with a ( scan ) tool.

 

As I stated in my original post, I did bleed the brakes (in order and multiple times), I did do the abs bleed (multiple times), and bench bled master cylinder (multiple times). I have now sent to a shop that has a pressure bleeder. Praying they get my nightmare resolved!

FYI...In my previous research I found the guy in the video posted here is incorrect that Ford never addressed the '06 - '10 models. They did recall many of them to flush out the Dot 3 fluid with Dot 4. Unfortunately, that recommendation doesn't apply to the 2012 that I am working on.

I will post on here the final resolution.

 

Sometimes we get lucky and can get away without using a scan tool to open the valves in the control unit, but not that often !

You can bleed the system until you are blue in the face and without opening the valves to allow the trapped air a means to get out, that is just the way it is
Need a capable scan tool to do the job right.

 

I stated in my original post and my follow up that I DID the abs bleed multiple times! And I do use a Snap On Modis Ultra scan tool. I own my own shop and have been doing brake work on all levels for years. Have never been completely stymied like I am with this one!

 

Don't feel badly, We have all been there , and many times at that.

Even a lot of pros hate to admit they are baffeled when they feel they installed good parts and know what they are doing and still have the problem.
An amateur will completely disregard the possibility of a new part being defective, but a pro hates to admit they could have arrived at a false diagnosis.

The only thing we do in a case like this is to go over everything we did and confirm every step as we go.
Until we do that we are only partially sure of what we feel is the real problem.
This is the proverbial time to go get a COUPLE of cups of coffee and review everything we did and the results , if they can be verified. A good part of the time is is simply something simple we overlooked and then the light comes on upstairs and we are glad this problem is solved.

 

Too bad you didn't say you had a scan tool right from the get go

 

I have run into a similar problem. Looks like you didn’t give a final update.

 

Hi everyone. Looking for somebody who may bleed or help with advice how to bleed Ford fusion hybrid 2012 brakes.
Willing to pay. Located in Federal Way, WA

What I did 3 times, but no success with multi routine calibration:
1. Installed used ABS unit, copied info from old ABS to new one.
2. Bleed all lines with pump, according the Ford service manual.
3. FORSCAN. Trying to do multi routine calibration, but it always fails.
4. Successfully ran service bleed with computer.
Brakes work fine, but still red brake logo and service brake system on the dash.