I have returned worn shoes one time. This time last year I bought a pair of shoes to wear to my DD's high school graduation. They hurt my foot so much in my very brief walk--my DH dropped us off 1/2 block from the entrance and picked us up about a block away, so I hardly walked in the shoes. They literally cut into my foot. I returned them to Kohl's and the lady started to argue, but I held my ground on that one. I explained how little I wore them and what they did to my foot. In general, though, I've been able to tell if shoes are ok when wearing them around my house and I would either return them without wearing them outside or I'd take the loss.