No matter if I set the setting for download to system or SD card, brave returns download error for any file to be downloaded from a website, whether pdf, jpg or docx.
Ask where to save is off, automatically open when possible (tried both on and off, no difference).
Secure DNS is set through Cloudflare.
Version 1.25.71 Chromium 91.0.4472.88
Android 11, Build / RP1A.200720.012
I don’t have this problem with other browsers.
I’m having the exact same issue and I’ve tried the same setting changes as you, too.
I replied here to see what answers you get. 
Same here, can’t figure it out. If I go to my download folder (on SD) the file is there, and it opens fine - but the download always shows as an error. Navigating to it to open it is a pain.
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