Wheel bearing assembly with dual telescoping outer rings and improved load support

A method for manufacturing and assembling an angular contact ball bearing of the type having a pair of ball rows arranged on pitch circles that define a pitch circle plane respective to each ball row and a pair of races disposed about a central axis, one race having a pair of axially outwardly facing ball pathways each of which is diagonally opposed to a respective one of a pair of axially inwardly facing ball pathways on the opposite race with a respective one of said rows of bearing balls engaged between each pair of diagonally opposed pathways along a respective one of a pair of oppositely sloped contact cones that form acute angles with said pitch circle planes, each pair of diagonally opposed pathways defining a clearance therebetween smaller than the ball diameter, and in which the axially outwardly facing ball pathways on said one race are both located axially inboard of the pitch circle planes of said ball rows so that moving either of said axially outwardly facing ball pathways axially apart from it's opposed pathway by a predetermined shift will enlarge the clearance therebetween to equal the ball diameter, comprising the steps of,

• selecting a ball row to be installed last,
• providing said one race with a primary cylindrical surface coaxial to said central axis and extending axially continuously from a point located between said ball rows to a radially extending outer edge located axially outboard of said selected ball row's contact cone, so that said contact cone intersects said primary cylindrical surface,
• providing a separate race piece that includes the axially outwardly facing pathway of the pair of diagonally opposed pathways respective to said selected ball row, said separate race piece having a secondary cylindrical surface thereon that closely radially engages within said primary cylindrical surface and which, when its pathway is engaged with said selected ball row and extends axially continuously from a point located between said ball rows to a radially extending outer edge that is axially spaced from said one race outer edge by at least said predetermined shift, so that the contact cone respective to said selected ball row also intersects said race piece secondary cylindrical surface at an area of close engagement with said one race's primary cylindrical surface,
• assembling the other of said ball rows between its opposed pathways,
• orienting said separate race piece coaxially to said central axis,
• sliding said separate race piece secondary cylindrical surface axially inwardly along said one race cylindrical primary cylindrical surface by at least said predetermined shift, thereby creating a clearance between the pathways of said selected ball row that is at least as large as said ball diameter,
• assembling said selected ball row against its axially inwardly facing pathway,
• sliding said separate race piece axially outwardly until its axially outwardly facing pathway engages said selected ball row, and,
• installing a rigid ring member axially solidly between said one race and said separate race piece outer edge,
• whereby said selected ball row is solidly engaged radially and axially between its diagonally opposed pathways in solid, load bearing engagement with both said separate race piece and said one race.