Minimized lateral clearance ball stud joint

A ball stud assembly configured to engage a component having a thickness, defining a stepped bore having a stepped bore inside diameter (ID) and extending through the thickness, centered on and extending along a bore axis, and having a reaction surface orthogonal to the bore axis, the ball stud assembly comprising:

• a ball stud extending along a stud axis and including:
• a ball first end;
• a threaded second end;
• a shank extending along the stud axis between the first and second ends, having a stepped shank shape, and configured to extend through the stepped bore and leave a gap between the stepped bore and the stepped shank shape, wherein:
• the stepped shank shape has a stepped shank outside diameter (OD);
• the stepped shank OD includes a first shank section having a first shank section OD and a second shank section having a second shank section OD;
• and
• the first shank section OD is larger than the second shank section OD;
• a flange arranged between the ball first end and the shank, having a flange surface arranged orthogonal to the stud axis, and configured to engage and abut the reaction surface;
• and
• a sleeve having a sleeve center axis and positioned on the shank;
• and
• a threaded nut configured to engage the threaded second end to tighten the ball stud on the component and deform the sleeve in the gap between the stepped bore and the stepped shape shank as the sleeve shifts, at least in part, from the second shank section OD to the first shank section OD such that the sleeve expands over the first shank section OD and fills at least part of the gap.

A method of generating a ball joint subassembly comprising:

• providing a component having a thickness, defining a stepped bore extending through the thickness, centered on and extending along a bore axis, and having a reaction surface orthogonal to the bore;
• engaging the component with a ball stud assembly including:
• a ball stud extending along a stud axis and having:
• a ball first end;
• a threaded second end;
• a shank extending along the stud axis between the first and second ends, having a stepped shank shape;
• a flange arranged between the ball first end and the shank, having a flange surface arranged orthogonal to the stud axis;
• and
• a sleeve having a sleeve center axis and positioned on the shank;
• inserting the shank into the stepped bore, such that the shank extends through the stepped bore and leaves a gap between the stepped bore and the stepped shank shape;
• and
• engaging a threaded nut with the threaded second end and tightening thereon to tighten the ball stud on the component, such that the flange engages with and abuts the reaction surface and the sleeve is shifted from one section of the stepped shank shape to another section of the stepped shank shape to thereby deform the sleeve in the gap between the stepped bore and the stepped shape shank and fill at least part of the gap.