Pneumatic booster output rod adjustment method

A method of adjusting the length of a vehicle brake booster output rod and assembling the same into a brake booster, the output rod being formed of a thermoplastic or thermoset material that is generally cylindrical in shape with a central longitudinal bore with an axial stop means, and the output rod having an insertable button having a head with an attached stem, the booster having a housing with a central opening surrounding the output rod with a surrounding first formed surface for mounting a master cylinder, the method in combination comprising:

• piloting a cutting tool by inserting an elongated member into the bore of the output rod;
• orienting the cutting tool by mating a fixture locationally associated with the cutting tool on the first formed surface of the vacuum booster housing;
• preloading the output rod with the elongated member by contacting means with the elongated member to simulate a spring load of a master cylinder;
• cutting the output rod with the cutting tool to a desired dimension corresponding to dimensions of the booster housing;
• removing the elongated member from the output rod bore;
• inserting the stem of the button into the output rod with a sheet material juxtaposed between the stem and the bore of the output rod causing an interference fit retaining the button in the output rod bore.