Brake Disc Caliper problems of the 2010 Ford Fusion Hybrid

The contact owns a 2010 Ford fusion. The contact stated while driving 35 mph and depressing the brake pedal, the brake pedal went to the floorboard. The brake warning light was illuminated, and the check braking system message was displayed. Additionally, the check engine and abs warning lights were illuminated. The contact activated the parking brake, and the vehicle came to a complete stop. The vehicle was towed to the dealer but no cause for the failure was found. The contact was informed that the caliper was leaking. The failure reoccurred and the vehicle was towed to the dealer. The contact was informed that the abs unit needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and advised to contact the NHTSA hotline. The failure mileage was 180,000.

Rear brake calipers and rotors rusted excessively fast, requiring a full rear brake job at 42,300 miles. Emergency brake and excessive rust was causing friction and sound, which led to the brake inspection. Faulty design where rear brakes need replacement after such as short period of time. When I told Ford dealership of this issue - rear brakes were "snapping" when first moving, I was told that all fusions have this rust buildup issue and that it was common. Took it into dealership and they just shrugged.

December 31, 2018 � while driving through city, I attempted to use the brakes and they did not response. I was able to cut the engine and pull over to the side of the road with spouse and children in vehicle. Error message stating abs brake system was not responding and a false positive tire sensor. January 2, 2018 � took car into dealership. Technicians unable to replicate problem though they found the error code in system. Technician replaced brakes, calipers, and reset error code. January 27, 2018 � same error message occurred with brakes failing in apartment parking lot. Car parked and error message went away. January 31, 2018 � same error message occurred and added an advancetrac service error message. Brakes failed to work. Upon researching issue with vehicle, I came across a consumer report which describes our problem exactly. Called dealership and currently working at trying to solve problem. Dealership stated if it was a software update, they wouldn't charge for the labor involved to update it. If software update failed to solve the problem, they would charge for assessment, parts, and labor to repair. Do not have a record of receiving mailing about the repair problem for this issue as the vehicle was purchased in 2013.