Socket assembly and method of making a socket assembly

1. A socket assembly, comprising:

a housing with an inner bore that extends along an axis from a wall at a generally closed first end to an open second end;

a ball stud having a ball portion which is received in said inner bore of said housing and a shank portion which projects out of said inner bore through said open second end;

a backing bearing disposed in said inner bore with an annular gap surrounding said backing bearing such that said backing bearing is movable in a radial direction relative to said housing and said backing bearing presenting a curved first bearing surface in sliding contact with an outer surface of said ball portion of said ball stud;

a radial ring having an annular shape disposed in said inner bore of said housing and presenting a second bearing surface that is in sliding contact with an equator of said ball portion;

an exit bearing made as a separate piece from said radial ring and having a curved third bearing surface in sliding contact with an opposite hemisphere of said ball portion from said first bearing surface;

wherein said exit bearing is spaced from said radial ring in an axial direction by a gap which surrounds said ball portion of said ball stud;

wherein said housing presents a shoulder that faces towards said open second end of said housing and wherein said radial ring abuts said shoulder; and

said backing bearing having a cylindrical outer surface with an outer diameter that is less than a diameter of said second bearing surface of said radial ring.

2. The socket assembly as set forth in claim 1 wherein said third bearing surface of said exit bearing is biased against said outer surface of said ball portion of said ball stud.

3. The socket assembly as set forth in claim 2 further including a dust boot which is sealed against said housing and said shank portion of said ball stud and which includes a spring at least partially embedded within a rubber body for biasing said third bearing surface of said exit bearing against said outer surface of said ball portion of said ball stud.

4. The socket assembly as set forth in claim 3 wherein said spring is a Belleville washer.

5. The socket assembly as set forth in claim 1 wherein said housing presents a radially inwardly extending lip at said open second end for trapping said exit bearing in said inner bore of said housing.

6. The socket assembly as set forth in claim 1 wherein said first bearing surface, said second bearing surface, and said third bearing surface all present a plurality of lubricant grooves for distributing a lubricant throughout said inner bore of said housing.

7. The socket assembly as set forth in claim 1 further including a thrust washer disposed between said wall of said housing and said backing bearing.

8. The socket assembly as set forth in claim 7 wherein said thrust washer or said backing bearing presents at least one lubricant channel for conveying a lubricant between said thrust washer and said backing bearing.

9. A method of making a socket assembly, comprising the steps of:

preparing a housing with an inner bore which extends from a wall at a generally closed first end to an open second end;

inserting a backing bearing with a curved first bearing surface into the inner bore of the housing such that an annular gap surrounds the backing bearing to allow the backing bearing to move in a radial direction relative to said housing within the inner bore;

inserting a ball portion of a ball stud into the inner bore of the housing and wherein the ball stud has a shank portion which extends from the ball portion out of the inner bore through the open second end of the housing and wherein a curved outer surface of the ball portion is in sliding contact with the first bearing surface of the backing bearing;

inserting a radial ring with a second bearing surface into the inner bore of the housing with the second bearing surface being in sliding contact with an equator of the ball portion of the ball stud such that the radial ring abuts a shoulder of the housing;

inserting an exit bearing with a curved third bearing surface into the inner bore of the housing such that the third bearing surface is brought into sliding contact with the curved outer surface of the ball portion of the ball stud and such that the exit bearing is spaced from the radial ring in an axial direction by a gap which surrounds the ball portion of the ball stud; and

wherein the backing bearing has a cylindrical outer surface which has an outer diameter that is less than a diameter of the second bearing surface of the radial ring.

10. The method as set forth in claim 9 further including the step of deforming the housing adjacent the open second end of the inner bore to trap the exit bearing in the inner bore.

11. The method as set forth in claim 10 wherein the step of deforming the housing is further defined as swaging the housing.

12. The method as set forth in claim 11 further including the step of sealing a dust boot against the housing and against the shank portion of the ball stud and wherein the swaging of the housing traps one end of the dust boot between a radially inwardly extending lip on the housing and an upper surface of the exit bearing.

13. The method as set forth in claim 12 wherein the dust boot includes a spring at least partially embedded in a rubber body and wherein the spring biases the third bearing surface of the exit bearing against the outer surface of the ball portion of the ball stud.

14. The method as set forth in claim 9 further including the step of injecting a lubricant into the inner bore of the housing.

15. The method as set forth in claim 9 further including the step of inserting a thrust washer into the inner bore of the housing before the step of inserting the backing bearing into the inner bore of the housing.

16. The method as set forth in claim 9 wherein said backing bearing is made as a monolithic piece of a substantially rigid material.

17. The method as set forth in claim 16 wherein said substantially rigid material of said backing bearing is a metal.