The brake pedal operates a hydraulic system that is used for 2 reasons. First, fluid under pressure can be carried to all parts of the vehicle by small hoses or metal lines without taking up a lot of room or causing routing problems. Second, the hydraulic fluid offers a great mechanical advantage; little foot pressure is required on the pedal, but a great deal of pressure is generated at the wheels.
The brake pedal is linked to a piston in the brake master cylinder, which is filled with hydraulic brake fluid. The master cylinder consists of a cylinder, containing a small piston and a fluid reservoir.
Modern master cylinders are actually 2 separate cylinders. The 2 cylinders are actually separated, allowing for emergency stopping power should one part of the system fail. The braking force is applied to one rear wheel and one front wheel in diagonal pattern. This system is known as the dual diagonal system.
The entire hydraulic system from the master cylinder to the wheels is full of hydraulic brake fluid. When the brake pedal is depressed, the pistons in the master cylinder are forced to move, exerting tremendous force on the fluid in the lines. The fluid has nowhere to go and forces the wheel cylinder piston (drum brakes) or caliper pistons (disc brakes) to exert pressure on the brake shoes or pads. The resulting friction between the brake shoe and wheel drum or the brake pad and disc slows the vehicle and eventually stops it.
Also attached to the brake pedal is a switch which lights the brake lights as the pedal is depressed. The lights stay ON until the brake pedal is released and returns to its normal position.
Each wheel cylinder in a drum brake system contains 2 pistons, one at either end, which push outward in opposite directions. In disc brake systems, the wheel cylinders are part of the caliper; there can be as many as 4 or as few as 1. Whether disc or drum type, all pistons use some type of rubber seal to prevent leakage around the piston and a rubber dust boot seals the outer ends of the wheel cylinders against dirt and moisture.
When the brake pedal is released, a spring pushes the master cylinder pistons back to their normal position. Check valves in the master cylinder piston allow fluid to flow toward the wheel cylinders or calipers as the piston returns. As the brake shoe return springs pull the brake shoes back to the released position, excess fluid returns to the master cylinder through compensating ports, which have been uncovered as the pistons move back. Any fluid that has leaked from the system will also be replaced through the compensating ports.
All brake systems use a switch to activate a light, warning of brake failure. The switch is located in a valve mounted near the master cylinder. A piston in the valve receives pressure on each end from the front and rear brake circuits. When the pressures are balanced, the piston remains stationary but when one circuit has a leak, greater pressure during the application of the brakes will force the piston to one side or the other, closing the switch and activating the warning light.
Disc brake systems also have a metering valve to prevent the front disc brakes from engaging before the rear brakes have contacted the drums. This ensures that the front brakes will not normally be used alone to stop the vehicle. A proportioning valve is also used to limit pressure to the rear brakes to prevent rear wheel lock-up during hard braking.