I'm running into the shim issue right now myself. Put in new Stens bearings and they must not be as thick as the OEM bearings, or the flange is thinner. With the washer installed and nuts tightened, the wheels have at least 1/16" of endplay on the spindle.
How can the large washer press against the outer race? The outer race rotates with the wheel, while the washer is fixed to the spindle. It seems like the only way this can work properly is if the large washer (or shim) touches the inner race and clears the outer race. Isn't that why the inner race protrudes out slightly more than the outer?
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