I brought my car in for a routine inspection. With only 32,459 miles (mostly highway) I wasn't expecting any problems. My mechanic found that my brakes were so rusted that the rear ones were fused together with rust. He was as surprised by this as I was. I saw the parts and have used this shop for years. He never saw anything like it in a car with such low mileage. Has to be a design flaw, and potentially very dangerous. So $900 later, I still have to worry that this will happen again. I doubt I'm the only one with this problem.

- Porter Corners, NY, USA

Got off the expressway and while stopped at light smelled "something". 3 blocks later at my house I felt the heat from the rear wheels on my legs and realized the smell was from rear brakes. Jacked up both rear wheels and found the wheels almost immovable. Rear pads worn down to 2-3mm! front pads still had 10mm of pad remaining on all four pads! no problem (or use of) with parking brake. Calibers had been sticking - dragging for quite some time to wear down to almost nothing while leaving front brakes with years left on them. Car was still in warranty.

- Bloomfiled Twp., MI, USA

My Ford Fusion was parked in the parking lot while shopping. Temperature approximately 15 degrees F. before going into the store, I had set the parking brake, as the car was parked on a slight incline. Upon exiting the store and restarting the vehicle, I disengaged the parking brake. However, the right rear brake did not disengage. Instead, a loud grinding sound occurred. The brake eventually disengaged, but by this time, the brake rotor was extremely hot. This had occurred one time previously, also on a cold day when the parking brake was set. The vehicle was taken into the dealership, and the dealer confirmed that the right rear rotor had overheated and been damaged. Pads and rotors were replaced. Upon picking the car up from the dealership, I drove approximately 3 miles to home, and when I exited the car, the right rotor was very hot and the smell of burning brakes was present in the garage. The left rotor was cool enough that I could place a hand on it for an extended period of time. I was unable to even momentarily touch the right rotor. In this particular case, I had not engaged the parking brake, as the vehicle was picked up from the dealership and the parking brake was not engaged. Vehicle had previously had brake pads and rotors replaced only 13000 miles previously (38000 miles) due to excessive rear brake pad / rotor wear.

- Grafton, WI, USA

The contact owns a 2010 Ford Fusion. The contact was driving approximately 70 mph and depressed the brake pedal, which abnormally traveled to the floorboard. The brake warning light also illuminated on the instrument panel. The contact applied the emergency brake to stop the vehicle and shut the engine off. After restarting the vehicle the failure recurred. The contact applied the emergency brakes and shut the engine off a second time. The contact restarted the vehicle and did not experience any further braking issues. The vehicle was not taken to the dealer for diagnostic testing. The vehicle was not repaired. The approximate failure mileage was 58,000.

- Fort Worth, TX, USA

When the weather gets below freezing the parking brake freezes - you can release the parking brake with the parking brake handle and the parking brake warning light goes off but the parking brake stays engaged with the driver unknowing that the parking brake did not release. When this happens the driver is not aware of the parking brake being engaged until the brakes get so hot that smoke begins to pour from the rear wheels with the possibility of this causing a fire from all the heat. Also when the parking brake does not release and you apply the brakes while driving the vehicle the brakes do not respond the same as when they are applied under normal driving conditions. This problem has been occurring every time the weather gets below freezing since the vehicle was bought new and the defect has been reported to the local Ford service department numerous times with them making an effort to correct this defect but it has not helped and the problem still exist. This vehicle is in North Alabama where the weather gets cold but not in an area in the northern states where the weather is much colder. This problem happened again this morning and the low temperature for the night was 30 degree F and it has not rained in over a week. I own three other vehicles that are parked in the same area as this vehicle that do not have any problem as with this vehicle.

- Muscle Shoals, AL, USA

The vehicle lost power steering, traction control, and brakes upon entering the freeway on ramp. To stop the vehicle and endangering other drivers, I was forced to crash into the concrete wall barrier on the drivers side of the on ramp. There were no warning lights on the dashboard until after coming to a stop and the engine died. At that point the warning lights came on.

- Mountlake Terrace, WA, USA

Pushing hard on the brake pedal causes it to go below the gas pedal letting my foot push both the gas and brake pedals at the same time.

- Falcon Heights, MN, USA

At 2000 miles had car back for brakes.its been back 8 times. They have cut the rotors and replaced pads and still jumps after about 5000 miles. Vibration in car that they couldnt find Y. replaced trottle body. There is an issue with the brakes they need to find out whats wrong. They have cut the rotors down to the point they replaced them and the ones on the front arent 6 months old and they cut them again.

- Nicholson, PA, USA