Good read except the bearing press method seem a little vague. I use the same method but using the old bearing as my "press washers" that way the pressure is applied to the outer race of the new bearing instead of the inner race which is a no-no.
With this mod is there still room for the outer seal to perform properly?I don't have a bearing press (or pull). It turns out my spare
pinion cup is a perfect fit to the extreme outer edge of the bearing(s); much more exacting than a big fat socket. I froze the bearing over night, and it only took a couple light taps with a rubber mallet on the back of the pinion cup to seat it in the pocket. I know whacking them in is a harry homeowner method (that's me), but I have many thousands of miles on both my interstates with the mod with no problem at all.
The exposed outer edge is a good question. I just gave them a coating of grease (once) and done. (and stay out of there with a pressure washer)
Back when this was originally discussed, someone pointed out a thin Nilos Ring could be added to cover the exposed end. Then there was a discussion of whether a few thousandths extra material should be cut off the cut down spacer to accommodate the few thousandths extra width of the Nilos Ring. Some said yeah, others no. It sounded like a good idea, but I didn't do it. Of course, you have to get the right one for the 5204 bearing (and I don't know which one that is).
I think it is noteworthy that of the many people who have done this mod, no one (to my knowledge) has ever come back with a failed double row mod (whether due to the exposed end or not).
Nilos Rings:
https://www.skf.com/binary/30-228382/950-710-Nilos_08.pdf
I don't know if this is the right type ring, just posted for an idea of fitment.

