Let me count the ways.
So I bought a rebuilt brake booster from RockAuto:
A-1 CARDONE - 535104 (53-5104) - Power Brake Booster $84.79 + $25.00 core = $109.79
I open the box and it's unpainted bare metal, and the metal that is exposed is deeply pitted. This thing was apparently a boat anchory rusty mess that they bead blasted back to "shiny". It's clear that someone sent in their completely tired worn out old dead booster as a core. There are also clear signs of physical abuse. Almost all of the clamshell retainer catches are split open and the case is dented where the master cylinder mounts. I guess I should expect some of that... As long as the pits don't go all the way through and split catch tabs still allow the clamshell halves to seal, I should get over it, right?
So I'm handling the unit and it feels slippery on the outside. Feels "silicone-ish"? I'm thinking I just clean it up and throw a quick coat of paint on it. I sprayed and cleaned and wiped and cleaned and sprayed and wiped... Then I sprayed a coat of rattle can black that instantly fish-eyed like I've never seen before. It's like a thousand guppies staring back at me. It's like someone dipped this thing in liquid teflon. Don't care anymore. It's mostly covered.
Bolt it into the car and while putting the master cylinder back into place I notice that the output shaft looks shorter than my original boosted. Sure enough, the shaft on my original booster sticks out about a quarter of an inch longer than the rebuild. Try to adjust the shaft length and it's frozen solid. Won't budge. Whatever... So my pedal engagement location will be a little different. I'll re-learn the new position.
Put the master cylinder in place and pull out of the garage. The pedal goes almost all the way to the floor before I get any braking action, and when I finally do get any action, there is no modulation. It's almost digital... Either coasting, or face through the windshield. No in-between.
Now for those of you who have been through this before, you already know where this is going, but I've never been here before. So, I pry the seal retainer out and remove the (rusty pitted) output shaft. Lots and lots of silicone grease, but you guessed it... no reaction disk. Can't see it in there anywhere and can't feel it. So I take the whole thing back off the car and shake the crap out of it for a frustratingly long time until the reaction disk finally falls out the hole.
Put the reaction disk back into place and put the booster back in the car. It works and will get me to my show this weekend, but I think I'm going to build some fixturing to take my old one apart. My old one is clean, un-dented, with the retaining clips intact. I think I'm going to investigate swapping over all the new rubber components from this rebuilt unit over to my old booster. Essentially paying $100 for a "rebuild kit" that I can apply to my original booster?
Unpainted, greasy, dented, case with snapped retainers. Rusty components where rubber seals are supposed to seal. Internals not assembled properly.
I hate rebuilt components... Starters, alternators, brake calipers, master cylinders, brake boosters. They all seem to be done by people who don't get paid enough to care what they're doing. Sheesh. Stark reminder of why I do my own work. Rant over.