360 Challenge/Stradale Manual build thread

Great guide for people who haven't done this. Getting the right puller really saves a lot of headache as you allude to!

 

Good job mate 👍 the alternator is one of the major parts that are subject to failure on a 360ch. They get stupid hot and very little air, I always have a spare one when racing.

 

So here is the rebuild of the alternator with some pictures and hopefully helpful points.

First off the case was cleaned with petrol and the bearing fit and stator fit surfaces were masked. The unit was then refinished.
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In front of the front bearing there are a couple of small washers and springs.
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The new bearing is installed by warming the holder in the oven a little, sticking the bearing in the freezer and then just dropping it in. Tap the bearing until the front face is flush. Don't tap the inner race, obviously.

Then fit the interference fit pins (note different length) back into the case with a smart tap.
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I cleaned up the slip ring and refinished the slightly flaky paint on the rotor using some red paint. It's a bit glossier than the factory red.
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Now you can push the slip ring through the bearing. Don't forget the thin washer. Tap the case over the shaft until the washer bottoms out. Obviously don't hit the slip ring!
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Now the stator and the rear case bearing can be fitted. Again use the oven to warm the case through to about 140 and freeze the bearing.

Work smartly - remove the unit from the oven, tap the bearing in and then without letting the case go cold fit the stator.

You need to make sure the stator lines up with the rear case so do a trial fit first and mark the case, and when you insert the stator make sure it goes in straight. Mine went in a bit crooked, got stuck and then as it all cooled I had to use a punch to tap it down so it was fully home. If it had gone in level it would have just plopped in I'm sure.
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Now you can screw the bearing holder down - internally I would use loctite 243 or similar on these screws.
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Now the four main bolts can be screwed in to retain the stator and the case halves can be brought together and tapped down onto the shaft.. Once these are close you can fit the 4 nuts and drag the whole thing together.
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The rear dust gasket can go on and the stator insulators
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Rectifier can get fitted, first making sure the stator connections are bent nicely to line up as replacement rectifiers can be slightly different sometimes.
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Now the new regulator can be installed along with the new brush box and dust cover.
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Finally the rear cover can be screwed on.
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I restuck the sticker on and fitted the pulley using my impact gun.
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Couldn't resist bolting it onto the Stradale engine - pleased - looks new and the whole job cost about $100 in bits which is about the cheapest thing I've ever done to the car!
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Last one from the front.
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Great work. One of those satisfying jobs!

 

Yes Mark I just have to keep focussed on the bit I'm working on. I don't know about you but if you step back and look at the whole project it gets a bit overwhelming when you have one single assembly stripped in to about 200 pieces.

The alternator job took ages because I had to get the replacement bits and the guy was really slow. The intake manifold reassembly is next and that will relieve me of hundreds of refurbished components sat on a tray. I think I'll feel better at that point as I can get cracking on rebuilding the driveshafts and then move to the engine for those seals and things that were mentioned earlier.

As an aside I recently bought a big Dewalt impact gun as I was struggling to remove the rear hub nuts using - well - anything. I cannot tell you how impressed I am with this thing. Literally it removed the hub nuts in about thirty seconds and I didn't even bother trying to dremel or heat the stakings in the nuts. Unbelievable and one of those tools that I'm now wondering how I've done without!

 

Just read your whole thread. Awesome work and thanks for taking the time to share with us on your Journey!!

 

That's very kind thank you. I'm trying to keep the diary up yes because although I know it's very detailled I always enjoy reading everyone else's rebuild threads so I felt it to be a duty to spend the time myself even though my car isn't a madly exotic classic like a Dino or a 512.

I'm certainly enjoying doing it but getting a bit jealous of the "here is my car in the sunshine threads" heheh

 

Looking good. I will slowly do all this refurbishing on my 360 myself as time goes by.

This thread got me motivated.

 

Haha yes it becomes a bit too much like work/the day job if there's too much going on. I like to try to limit that and keep enjoying it by focusing on a few things at a time.

I have a compressor in my workshop with a range of attachments but that pre-dates the newer battery powered stuff which really is awesome. I could do with a battery impact gun for the convenience aspect.

Love DeWalt tools!

 

What a thread! Insane detail. I didn't notice anyone mention the GT3 in some of the pics

Anyway thanks for all the details and I look forward to your future updates.

 

Well it's been a bit of a while but I've been doing a few bits to the car in the background whilst my work has been really hectic.

First off I refurbished the drive shafts. They were badly corroded on the outboard end.

Nasty
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