I've changed all the braking system on Fred Fusion, every thing is brand new, I fitted the rear brake cylinders & the short hand brake cables today.

Bleeding off the whole system twice with fresh Dot4, with the pedel firm.

Although the brakes work Inc the handbrake, the brakes don't feel strong enough, it's like it's missing something.

Can only think that the master cylinder is passing, either seals are split, or the whole unit needs changing.

No leaks anywhere, all good & dry, reservoir all Okay no loss of liquid even on a test drive & harsh braking.

Ideas welcome 😕🤔

It may just be that the brakes need time to bed in.

Did you use a good make of pads, or "el cheapo"?

Hi thanks for the reply, the rear shoes were all good & original just needed refacing, but all other parts were new & not cheap parts.

Front everything brand-new "Brembo" braking which I've used on all my cars & works.

In short, new calipers, pads,hoses,fixed lines,rear brake cylinders, rear drums, rear spring kit for the shoes.

All working fine, but the braking force is lacking, certainly no leaks, but you can't rely on new parts working.

I'm wondering if the master cylinder is at fault, a faulty internal seal not transfering enough pressure, in other words pressure escaping backwards.

In my case, i took car to garage (after repeated bleeding of brakes) and they bled the abs pump.

Resolved my issue after replacing front caliper and a rear cylinder.

Brembo pads tend to be hard, intended for good performance when used hard and don't tend to work well until they are hot.

You would be better off fitting standard pads, unless the car is used for competition.

1 hour ago, fullwavebridge said:

In my case, i took car to garage (after repeated bleeding of brakes) and they bled the abs pump.

Resolved my issue after replacing front caliper and a rear cylinder.

This can be done DIY using Forscan on many models.  Though I'm not sure if a 2006 Fusion will be on there as service procedures get thinner in the earlier models.

6 hours ago, TomsFocus said:

This can be done DIY using Forscan on many models.  Though I'm not sure if a 2006 Fusion will be on there as service procedures get thinner in the earlier models.

Yes i found out later, but at the time i didn't have Forscan.

Is it called purging the pump ?

4 minutes ago, fullwavebridge said:

Yes i found out later, but at the time i didn't have Forscan.

Is it called purging the pump ?

Forscan call it a Service Bleed.  Though it might be listed under different names on non-Ford tools.

Hi thanks for the replies, having looked through the websites, there is a quick fix.

The scan opens the abs pump allowing bleeding of the system, but you can trick the system by rapid pumping of the brake pedal between each succession of bleeding, this creates full pressure in the system which is enough to lift the pump.

Haven't tried it, but will let you know tomorrow.

Didn't take Fred out today poured down with rain.

Don't want a garage visit for something which can be fixed at home.