Hey Jerome,
Sorry to hear your troubles. I don't know about the corrupt card deal, but by chance had you loaded a saved ghost to chase or done the analyzer of a lap? That sometimes causes me trouble with replays not saving correctly.
The brake coming on at random is a common complaint with the DFP. There is a lot of information on how to fix it. I think there is a sub-forum somewhere here on GTP?
But anyway, normally the problem is in the wire routing inside the foot pedal housing. It is routed so tight that it pulls on the potentiometers inside and causes position errors. You just need to loosen up the wires and tape them in place on the inside of the housing. Also, make sure that the first time you fire up the DFP for a session, and go out on track, you do a full brake/letoff. Not a partial brake! This teaches it what the full range is from what I have heard, will be more stable. One other thing is if you crash and exit out with the red brake bar on, it may act weird afterward. For any random brake coming one, try unplugging the footpedals at the wheel, and plugging back in. This resets them, and sometimes works pretty well.
Hope this helps.
MS