Abstract: A method of manufacturing vehicle brake boosters includes load testing a plurality of reaction discs and sorting the load-tested reaction discs into multiple, separate batches based on the load test results. A first batch of plunger plates is formed to an axial length to correspond with a first of the separate batches of reaction discs. A first batch of the vehicle brake boosters is assembled with a first one of the multiple, separate batches of reaction discs and the first batch of plunger plates to achieve a target jump-in force. A second batch of plunger plates is formed to an axial length to correspond with a second one of the separate batches of reaction discs. A second batch of the vehicle brake boosters is assembled with a second one of the multiple separate batches of reaction discs and the second batch of plunger plates to achieve the target jump-in force.

Abstract: A method of manufacturing vehicle brake boosters includes load testing a plurality of reaction discs and sorting the load-tested reaction discs into multiple, separate batches based on the load test results. A first batch of plunger plates is formed to an axial length to correspond with a first of the separate batches of reaction discs. A first batch of the vehicle brake boosters is assembled with a first one of the multiple, separate batches of reaction discs and the first batch of plunger plates to achieve a target jump-in force. A second batch of plunger plates is formed to an axial length to correspond with a second one of the separate batches of reaction discs. A second batch of the vehicle brake boosters is assembled with a second one of the multiple separate batches of reaction discs and the second batch of plunger plates to achieve the target jump-in force.

Abstract: A method of manufacturing vehicle brake boosters includes load testing a plurality of reaction discs and sorting the load-tested reaction discs into multiple, separate batches based on the load test results. A first batch of plunger plates is formed to an axial length to correspond with a first of the separate batches of reaction discs. A first batch of the vehicle brake boosters is assembled with a first one of the multiple, separate batches of reaction discs and the first batch of plunger plates to achieve a target jump-in force. A second batch of plunger plates is formed to an axial length to correspond with a second one of the separate batches of reaction discs. A second batch of the vehicle brake boosters is assembled with a second one of the multiple separate batches of reaction discs and the second batch of plunger plates to achieve the target jump-in force.

Abstract: A method of manufacturing vehicle brake boosters includes load testing a plurality of reaction discs and sorting the load-tested reaction discs into multiple, separate batches based on the load test results. A first batch of plunger plates is formed to an axial length to correspond with a first of the separate batches of reaction discs. A first batch of the vehicle brake boosters is assembled with a first one of the multiple, separate batches of reaction discs and the first batch of plunger plates to achieve a target jump-in force. A second batch of plunger plates is formed to an axial length to correspond with a second one of the separate batches of reaction discs. A second batch of the vehicle brake boosters is assembled with a second one of the multiple separate batches of reaction discs and the second batch of plunger plates to achieve the target jump-in force.

Abstract: A brake booster and a method of assembling an output member thereof within a bore of a valve body. In this brake booster, a reaction disc engages a holder of a reaction transmitting assembly which is connected to a plunger of an input member. A guide is attached to a cylindrical head on a shaft of an output member by hooks on the end of a first plurality of legs that extend in a first direction from a cylindrical base. A second plurality of axial legs that extend from the cylindrical base in a second direction are connected to a support ring. The cylindrical base is located in the bore by the support ring being positioned on a shoulder in the valve body by a return spring such that a series of arcuate tabs on the cylindrical base urge a reaction disc retained by the cylindrical head into engagement with the holder.

Abstract: A brake booster (12) having a housing (14,16) with a control valve (70) located in an axial bore (54) of a hub (50) carried by a movable wall (22,24). The movable wall (22,24) separates the interior of the housing into a first chamber (26,26′) and a second chamber (28,28′). The control valve (70) in a first mode communicates the first chamber (26,26′) with the second chamber (28,28′) to provide for equal pressures therein and in a second mode communicates the second chamber (28,28′) with a surrounding environment to create a pressure differential across the movable wall (22,24). A reaction member (96) carried by the movable wall (22,24) communicates an operational force created by the pressure differential into an output push rod (94).

Abstract: A brake booster (12) having a housing (14,16) with a control valve (70) located in an axial bore (54) of a hub (50) carried by a movable wall (22,24). The movable wall (22,24) separates the interior of the housing into a first chamber (26,26′) and a second chamber (28,28′). The control valve (70) in a first mode communicates the first chamber (26,26′) with the second chamber (28,28′) to provide for equal pressures therein and in a second mode communicates the second chamber (28,28′) with a surrounding environment to create a pressure differential across the movable wall (22,24). A reaction member (96) carried by the movable wall (22,24) communicates an operational force created by the pressure differential into an output push rod (94).

Abstract: A brake system has a brake booster secured to a dash panel which separates an engine compartment from a passenger compartment of a vehicle. A bracket off-sets the booster into the engine compartment from the dash panel. A cylindrical body has a flange on a first end located between the housing of the brake booster and the bracket. The cylindrical body has a partition wall located between the first end and a second end and a radial opening located between the partition wall and the second end. The partition wall has a central opening through which an input rod extends to provide a valve with an input force. An end boot, secured to the second end of the cylindrical body and the input rod, forms a resonant chamber within the cylindrical body. The radial opening provides unrestricted communication air from the engine compartment to the resonant chamber while the central opening forms an orifice to control the air flow from the resonant chamber into the valve body.