Method of manufacturing brake boosters

A method of manufacturing a series of vehicle brake boosters, each having a brake input member configured to receive a braking input force, a brake output member configured to supply a braking output force in excess of the braking input force, an elastic reaction disc, and a plunger plate, the method comprising:

• load testing a plurality of the reaction discs for the series of vehicle brake boosters, and sorting the load-tested reaction discs into multiple, separate batches based on the load test results;
• forming a first batch of the plunger plates for the series of vehicle brake boosters to an axial length to correspond with a first one of the separate batches of reaction discs;
• assembling a first batch of the series of vehicle brake boosters with the first one of the separate batches of the reaction discs and the first batch of plunger plates to achieve a target jump-in force;
• forming a second batch of the plunger plates for the series of vehicle brake boosters to an axial length to correspond with a second one of the separate batches of reaction discs;
• and
• assembling a second batch of the series of vehicle brake boosters with the second one of the separate batches of reaction discs and the second batch of plunger plates to achieve the target jump-in force.