Three problems related to brake drum wheel cylinder have been reported for the 2009 Mercury Milan. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2009 Mercury Milan based on all problems reported for the 2009 Milan.
I have been having an ongoing issue with my braking system on the 2009 Mercury Milan. It usually starts as having to activate the brakes fairly quickly (either slamming on the brake in emergency, or stopping over a dirt road or slowing over a speed bump). The brake pedal will activate the abs (pump 3-4 times) and depress clear to the floor without actually stopping the vehicle. Then immediately after and until I have the brake lines bled there is 0 pressure in my brake pedal (pedal continues to go to floor without completely stopping the car). I recently had the master brake cylinder replaced which only corrected the problem for a short time and have just had to take it back to the shop for the same issue. They told me everything "seems fine" and they can't find another issue with the system. Clearly this is a safety risk and Ford needs to do a recall on this issue!.
When braking hard, the brake pedal went down 2-3 more inches more than normal before I could brake the car. Added effort was needed to stop the car. The pedal returned to normal after 2-3 days. Happen two more times over months, but last time did not return to normal. Ford dealer replaced master brake cylinder, rear pads, and rear brake lines. Did not solve the problem. Brakes work, but added pedal travel still exists and added brake effort needed.
As reported by several other Milan owners , which NHTSA is currently investigating, my brakes are "soft". While in motion and attempting to brake, the petal goes to the floor, leaving me to only hope my car will stop in time to avoid personal or vehicular injury. I am a retired Ford engineer and know this is an fmvss, serious violation. I have taken it to three repair shops , including two Ford dealers, and each has told me I need a new hydraulic control cylinder which is about a $2000 repair. This repair cost is about half the current value of the vehicle. I am hoping that your investigation will force a recall repair at little or no cost to me. I purchased this vehicle new from Ford. Please advise any other actions I need to pursue.