Abstract: A drum braking system includes, a brake lever assembly having a brake lever and a cable assembly. The brake lever includes a base member, a guide spring support attached to the base member, and a connector structure attached to the base member. The cable assembly includes a guide spring supported by the guide spring support, and a cable extending through the guide spring. The guide spring support defines an aperture having a perimeter. The guide spring support includes a first tab, a second tab, and a third tab each extending from the perimeter. The guide spring extends through the aperture so as to be positioned in contact with each of the first tab, the second tab, and the third tab. The connector structure has defined therein a slot having a reduced width portion and an increased width portion. The cable further extends though the reduced width portion of the slot.

Abstract: A method of manufacturing a diaphragm backing plate for use in a brake booster comprising the steps of moving a coil of metal having parallel first and second sides that define a first width to a first station. Applying a stamping force to remove a section from the coil of metal and create a first plate defined by equal and parallel sides that are connected to each other by an arcuate segments each having a radius that is approximately equal to one-half of the width of the coil plus a minimum width of a lip. Moving the plate to a second station and thereafter rolling a peripheral surface thereon to define a uniform diameter for the plate that is approximately equal to the first width of the roll less twice the minimum width for the lip.

Abstract: A brake booster having a first shell joined to a second shell through a flange (26) on the first shell and a peripheral surface (204) on the second shell. Axial slots (36,36?, . . . 36n) on the flange that extend from an opened end toward a shoulder engage radial slots (38,38?, . . . 38n) to create a first plurality of arcuate projections (40,40?, . . . 40n) that are sequentially separated from a second plurality of arcuate projections (42,42?, . . . 42n). Each arcuate projection (40) has parallel sides that extend from a radial plane (11) on the flange while each arcuate projection (42) has first and second radial tabs (44, 46) thereon. Each arcuate projection (40) is deformed into sealing engagement with an edge (206) on the peripheral surface (204) to position the peripheral surface (204) under the flange while creating an axial gap (x) between the radial tabs (44,46) and the edge (206) to provide a visual inspection of the sealing engagement.