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.

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.

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.

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.

A vehicle brake booster includes a brake input member configured to receive a braking input force and a booster housing divided into a first chamber adjacent the brake input member and a second chamber remote from the brake input member. A poppet valve includes a poppet valve body and a poppet seal, the poppet valve operable to maintain separation between pressure and vacuum during assisted braking and further being operable to enable evacuation of the air from the first chamber through one or more side ports of the poppet valve body upon release of the braking input force and completion of the assisted braking A restrictor element provides a predetermined release speed for the booster. The one or more side ports define a total flow resistance of the poppet valve body which is less than an effective total flow resistance of the poppet valve body set by the restrictor element.