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Hudson
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480-490
Service Manual
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Hudson 480-490, 480, 490 Service Manual

This manual provided by
HET Club member
Drew Meyer
I
FOREWORD
ORGANIZATION
Much has been written and spoken about the proper operation of a service department and the factors
which make such an operation profitable and successful.
Some of the more important factors are:
1. Shop Appearance
2. Proper Service Equipment
3. Personnel - Proper dress Neat appearance
APPEARANCE IS IMPORTANT
Customers are inclined to judge the quality of your work by the appearance of your shop. In looking over
your operation from an appearance standpoint, the first thing to check is identification. The Hudson Service sign is designed to identify your place of business as an authorized Hudson service station and will not only create confidence in the minds of the owners but will guide transient owners and new customers to your door.
Next in order is an inspection of the service department and shop. Is it as clean and attractive as soap and water and paint can make it? Hot water, cleaning compound, and a few gallons of paint will work wonders in the appearance of a service department and will return their cost many times in increased customer satisfaction and comfort.
An accumulation of junk and broken and discarded parts and tools is an eyesore in any shop. An easily accessable junk box outside the building, near an alley for easy unloading, is the best answer. Make each member of the service staff responsible for removing his own junk parts. Remember - - - - - - first impressions are lasting.
EQUIPMENT
Adequate equipment provides the means for good service men to perform first class service work at a
minimum of cost. Car owners, thru costly experience with poorly equipped shops, have become tool and equipment conscious. Therefore, proper tools and equipment are a strict necessity. We must show our customers that we have the equipment by proper arrangement and display.
II
INTRODUCTION
The series 480 and 490 Hudson is built of a completely new principal and design, and is not just another
motor car. The "Monobilt" body and frame construction differs greatly from the conventional motor car employing separate body and frame units. Naturally being so totally different, a new approach to the repair of body damage is necessary. These differences, however, do not make the repair job more difficult or more costly to complete. In many instances the time required on a specific operation is less than that required on previous models.
Once you are completely familiar with the Monobilt body and frame construction of the 480 and 490 series Hudson, when you have learned the placement of all of the various parts and assemblies and how they fit together to make the rugged and sturdy Monobuilt all steel unit, then you will go about each job with complete confidence.
The information contained in this body manual is to be used as a guide for servicing the 480-490 series Hudson.
The manual has been divided into four parts:
Part one - includes technical information, model designations, body paint color code, estimating and ordering of repair parts, car serial number identification, and trim material color chart. Illustrated in this section are the various body types, positions of body welds and top panel soldering.
Part two - includes removal and installation of sheet metal parts: viz., fenders, rocker panels, hood, grille, rear compartment; also interior hardware, trim, instruments, headlining, door locks, handles, and regulators; and front wheel alignment.
Part three - includes body repair and metal finishing, consisting of tool application, bumping, dinging, solder filling, shrinking, fender welding, filing, sanding, and removing minor dents. Part three also includes body alignment checking, door repairs, and door alignment.
Part four - comprises the convertible 480-490 series, consisting of complete information on repairs of hydraulic and electrical units, removal and installation of component assemblies and parts, top adjustments, and trouble shooting.
Illustrations and pages of this manual are numbered consecutively. An alphabetical index is placed in the front of the manual for easy reference.
A thorough study of the operations and necessary tools and equipment will enable the Hudson Service dealer to perform reliable service at reasonable cost.
INDEX
III
Adjustment, door striker folding top hood radio weather control door window windshield wiper arms top control rod Alignment, body door frame front wheel rear curtain, convertible Battery gravity Bleeding the hydraulic system Body aligning Body repair Breaker, circuit Brazing Bumping Camber Caster Cigar lighter Circuit breaker Circuit breaker- check, convertible Cleaning upholstery Clock Coil spring sag Cold shrinking Construction, body Color guide Colors, body Convertible brougham Curtain, rear Cylinder, door lock Cylinder, hydraulic Cylinder, solenoid Dimensions Dinging Door aligning Door lock cylinder glass front glass rear lock outside handle remote control striker plate adjustment striker plate trim panel ventilator wing ventilator wing regulator window regulator front window regulator rear
Page
27,60
74
23 38 40 88
36
74
48,62-64
58
60-61
1,41-43
85 90
94 62 47
32,41,88,91
54
47-54
1,41-43 1,41-42
33
32,41,88,91
91 44 34 43
53,55
50
9,25
3-5
13,67-96
84-86
27,83 69,74-78 77,92-93
2
52,53
58 27,83 31,77 31,77
27,29,83
28-82
30,83
27-60
27
28,31,81,82
30,78
30
28 29
Door lock lubrication Door straightening Door trim panel - Convertible . Door window regulator hydraulic convertible cylinder Elastic metal Electrical system checks - convertible Fender, front rear Fender and grille side support Fender stone guard and panel - front Fender tie panel Filing Finish, care of Fluid, hydraulic Fluid pressure Flux Forging welds Frame alignment Front suspension Fuel gauge Fuses Glass, door quarter window rear window windshield Grille, radiator radio speaker Ground, cylinder solenoid . . . pump motor Gauge, fuel rear curtain temperature Handle, door Headlining Heat shrinking Hood Hood adjustment lock upper support lock lower support Hydraulic pump prime Hydraulic system check - convertible Hydro-Lectric Motor and pump assy Hydro-Lectric, service system Ignition switch Instruments Instrument panel Insulation Jacks, body Lamps Lock, door
Page
83 59
81
75-77
77
77
47
91 20
19
23
20
24
52,53,57
45
76,90-91, 94
70,76,93
54 57 60
1,41-43
35 41 31,77 31,32 32
26 22 37 77,93
70,71,72
35 85 35 28,82
24-27
53,55 23 23 23 23 94
93
70,72
90
67-96
32 32 32 65
49,51-52
2,33,34
27,29,83
Window operating switches-convertible
IV
Lubrication, body hydraulic cylinder lock Metal finishing Model designations Monobuilt body Motor, pump Motor solenoid switch check-convertible Normalizing Paddle, solder Paint Paint - care of finish Panel, instrument switch trim Parts, repair Pivot pin inclination Pulley adjustment Pump hydraulic Quarter trim panel Quarter window trim panel window regulator Quarter window - convertible Quenching Radiator Radiator grille baffle (upper) . front splash guard and moulding grille center bar (upper) Radiator splash guard moulding Radiator "U" channel Radio Radio - installation automatic tuning Rear window Refilling the hydraulic system convertible Remote control, door Regulator, door wing front door hydraulic quarter window rear door Resealing Reservoir, fluid Rheostat, lamp Riding height and coil spring sag Roof bows Roughing Sanding Sealing Seat cushion front and rear back, front and rear Serial numbers Shrinking - cold hot Solder filling Speedometer
Page
16
75, 77
83
47-58
1
II, 10
68, 69,70-72, 90
92
64
9, 54
3-6,45
45
32,34,37
34
28,31,81,82
6, 19 42 36
70,72,90,94
82 31 31
32, 79
79
54,56
22
22
22
22
23
22
36, 39
36 38 32
94 30, 83 30, 78
28
69,75-78,86,88
32,79
29 64
70,71,90-91
33
43
9, 25
48, 58
53,58
65 82 82
1,6
55 55
52,53,54
34
Spindle pin inclination Splash guard Spot weld positions Springs, front rear window regulator Starter switch Stone guard Striker, door Switch, ignition light motor solenoid starter top operating window operating Technical Information Temperature gauge Tie rods Tools - application of Tools - body clip removing headlining switch removing Toe-in Toe-out Top adjustment Top control rod Top covering installation Top, folding Top operating cylinder Top operating switch check Top operating valve and switch Torch soldering Tramming Trim material Trim panels Trouble shooting Upholstery cleaning Upholstery material Valve, cylinder solenoid pressure relief top operating Weather control Wedge, hydraulic Welding Wheel bearings Window adjustment Window lift switch-check-convertible
Window regulator solenoid check Windshield Windshield wiper Windshield wiper control wiper cable tension Wing, door ventilator Wiring
Page
1, 41-42
22, 23
13-15
2 43
2
69, 75, 76
32 20
27, 60
32 32
68, 69, 70, 92
32 72, 73, 90, 91-92 69, 79-81, 88, 91
1
35
1 50 49 78 25
80, 81, 91
1, 41, 43
43
86 87
73, 74, 91
84
68, 70-75, 84, 16
74, 75
91
72, 73, 74, 93
52, 53, 54
62
7
28, 31, 81, 82
95-96
44
7
77, 92-93
70 93
68, 72, 73, 90, 93
39, 41
49
53, 54, 57
1
88 89
91
79, 80
92 26 33 33 36
30, 79
88, 89, 90, 91, 93
BODY MANUAL 1
NOTE: Caster must not vary
more than ½ between sides
Tie Rod End Adjustment (As
seen from right side of car
):
MODEL DESIGNATIONS AND SERIAL NUMBERS
The new Hudson models are produced in the Super and Commodore Series and carry the following designations:
Hudson Super Six Series - Model 481 - 491
BODY TYPES
Brougham 4 Door Sedan 3 Passenger Coupe Club Coupe Convertible Brougham
4 Door Sedan Club Coupe
4 Door Sedan Club Coupe
4 Door Sedan Club Coupe Convertible Brougham
STARTING SERIAL NO’S
481101 - 491101 and up
Hudson Commodore Six Series - Model 482 - 492
482101 - 492101 and up
Hudson Super Eight Series - Model 483 - 493
483101 - 493101 and up
Hudson Commodore Eight Series - Model 484 - 494
484101 - 494101 and up
The car serial number, which is also the engine number, is stamped on a metal plate attached to the right front
door hinge pillar post. In the car numbering system, the first three digits of the serial number indicate the series and model while the remaining digits represent the actual car number. As the cars leave the production line, they are numbered in consecutive order, regardless of series or model. As an example, the car built after serial number 491999 would be numbered 4911000 instead of 492000. Code letters or numbers indicating the car paint color option are stamped on the upper hinge of the right front door.
TECHNICAL INFORMATION
FRONT SUSPENSION SIX CYLINDER EIGHT CYLINDER
Type Camber Caster
Toe-in Spindle pin inclination Spindle pin thrust bearing Wheel Bearing - Type End Play Tie Rod End (Type) Number of Tie Rods
Independent Coil Springing 1/2° to 1-1/2° 1/2º to 1-1/2°
0" to 1/16" 3° - 36' Ball Adjustable tapered roller .001 to .003 Plain Bearing 2
Independent Coil Springing 1/2º to 1-1/2º 1/2º to 1-1/2 ° sides
0" to 1/16" 3° - 36' Ball Adjustable tapered roller .001 to .003 Plain Bearing 2
To lengthen To shorten
Turn clockwise Turn counter-clockwise
Turn clockwise Turn counter-clockwise
2 BODY MANUAL
FRONT SPRINGS SIX CYLINDER EIGHT CYLINDER
Type Free Height Height under curb weight
REAR SPRINGS
Type
Covers Length and Width Number leaves Shackles Lubricant-Shackles and Leaves
Headlight (Sealed Beam Type) Hood Light Parking Light with Direction Indicator Tail and Stop Light License Light Dome Light-Front Rear Quarter Lights (2) Clock Speedometer Instrument Cluster Direction Indicator Ignition Lock Courtesy Lights Fog Light (Sealed Beam) Spot Light Sealed Beam) Parking Light Generator and Oil Indicator Radio Headlight Beam Indicator
Coil 16-5/16" 9-9/16"
Semi-elliptic Covered Uncovered Metal 54" - 1-3/4" 8 Silent "U" Threaded Viscous chassis lube
LAMP BULBS
No. 4030 55
1154 1154 63 87 81 55 55 55 55 55 87 4015-A 4535 63 55 55 55
C. P. Sealed 2
21-3 21-3 3 15 6 2 2 2 2 2 15 Sealed Sealed 3 2 2 2
Coil 16-5/16" 9-9/16"
Semi-elliptic Covered Uncovered Metal 54" - 1-3/4" 8 Silent "U" Threaded Viscous chassis lube
Base Sealed Single
Double Double Single Single Single Single Single Single Single Single Single Sealed Sealed Single Single Single Single
DIMENSIONS (6 Passenger 4 Door Sedan)
Wheel Base Overall Length (Including Bumpers and Guards) Overall Width (Including Fenders) Tread Front Rear Road Clearance Front Rear Overall Height-Road to Roof
SIX CYLINDER EIGHT CYLINDER
124"
207-1/2" 77"
58-1/2" 55-1/2"
8" 8"
60"
124"
207-1/2" 77"
58-1/2" 55-1/2"
8" 8" 60"
BODY MANUAL 3
1948 HUDSON BODY COLORS
Standard Single Body Colors Option Special Two-Tone Combinations Option
Banner Blue Jockey Blue Gallant Gray Quartermaster Gray Piedmont Green Savoy Green Maroon-Deep Ruby Red* Navahoe Bronze Harness Tan Ebony Black
* Ruby red is a special body color and is listed above only to complete the two-tone combination with maroon-deep.
B
M
RR
G Q
N H K
Upper Body Color
J
P S
Lower Body Color Upper Body Color Lower Body Color Upper Body Color Lower Body Color Upper Body Color Lower Body Color Upper Body Color Lower Body Color
SPECIAL SINGLE BODY COLORS
JB
QG
SP
RM
HN
Body Colors Option Option on Models
Ruby Red* Platinum
RR CC
481-P - 482 - 483 - 484 Broughams Sedans, Bus. Coupes, Club Coupes, and 481-P - 482 - 484 Convertible Brougham
ORDERING PAINT OR PAINTED PARTS
When ordering paint or painted parts, special care should be exercised in listing the paint option code and the
paint color or colors. This information is valuable, especially when the automobile has a two-tone color combination. Always use the charts furnished herein and be sure that every repair order including paints has the complete, detailed information.
Hudson body colors are pure virgin lacquers. For the maintenance and protection of these high quality finishes refer to Page 45 of this manual under the heading "Paint - care of finish."
4 BODY MANUAL
CHART No. 1
1949 HUDSON BODY COLORS
Standard Single Body Colors Option Special Two-Tone Combinations Option
Brigantine Blue** Jersey Blue Glowing Gray Queenstown Gray Piedmont Green** Savoy Green** Nomad Bronze** Holster Tan** Maroon - Deep** Ruby Red* Ebony Black
* Ruby red is a special body color and is listed above only to complete the two-tone combination with maroon-deep.
**Not available on convertible brougham.
M
RR
G Q
N H
K
B
J
P S
Upper Body Color Lower Body Color Upper Body Color Lower Body Color Upper Body Color Lower Body Color Upper Body Color Lower Body Color Upper Body Color Lower Body Color
SPECIAL SINGLE BODY COLORS
Body Colors Option Option on Models
JB**
KG
SP**
HN**
RM**
Ruby Red* Platinum
*Refer to Page 5 for 1949 body color option information.
RR CC
491-P - 492 - 493 - 494 Broughams Sedans, Bus. Coupes, Club Coupes, and 491-P - 492 - 494 Convertible Brougham
CHART No. 2
1949 HUDSON BODY COLORS
Standard Single Body Colors Option Special Two-Tone Combinations Option
Pacemaker Green Opalescent Sierra Green Opalescent Naples Tan Opalescent Hardwood Tan Opalescent Gull Gray Opalescent Quebec Gray Opalescent Burgundy Maroon Opalescent Radiant Red Opalescent* Brazilian Blue Opalescent Jet Blue Opalescent Ebony Black
8 10 7 3 2 9 6 16 1 4 5
Upper Body Color Lower Body Color Upper Body Color Lower Body Color Upper Body Color Lower Body Color Upper Body Color Lower Body Color Upper Body Color Lower Body Color
14
11
13
15
12
SPECIAL SINGLE BODY COLORS
Body Color Option Option on Models
BODY MANUAL 5
Radiant Red Opalescent Gray Gold (light) Opalescent
16 17
491P - 492 - 493 - 494 Broughams, Sedans, Bus. Coupes, Club Coupes, and 492-P ­492 - 494 Convertible Brougham.
1949 BODY COLOR OPTION INFORMATION
It will be noted that the 490 Series Hudson has two methods of paint option identification. On approximately the first 100,000 490 Series cars an ALPHABETICAL paint option was stamped into the right hand front door upper hinge, body half. (See 1949 Body Color Chart No. 1)
Body color Chart No.2 lists the new body colors and the NUMERICAL options used on the 490 Series Hudson after approximately the first 100,000 cars. This numerical paint option is also stamped into the body half of the right hand front door upper hinge.
EXAMPLE: (Chart No. 1)
Single Body Color Option
Brigantine Blue Jersey Blue
Two-Tone Combination
B
J
Brigantine Blue Jersey Blue JB
Option
Either brigantine blue or jersey blue may be used as an all over body color in which case a single "B" or "J" will
be stamped into the right hand front door upper hinge. When both brigantine blue and jersey blue are used to­gether as a two-tone combination, the letters "JB" will be stamped into the right hand front door upper hinge.
EXAMPLE: (Chart No. 2)
Single Body Color Option
Pacemaker Green Opalescent Sierra Green Opalescent
The application of the numerical option colors is handled in the same manner as is the alphabetical options outlined above.
8 10
Two-Tone Combination
Pacemaker Green Opalescent Sierra Green Opalescent 14
Option
6 BODY MANUAL
jobs, or lose money on them if you do get them. A successful future for your business depends upon the correctness
In the event a new NUMERICAL body color is used in two-tone combination with an old ALPHABETICAL body color, the option stamping will appear as below:
Brazilian Blue Opalescent (New) 1 Jersey Blue (Old) J
This will be the only occasion when both SINGLE body color options used in two- tone combinations will ap­pear stamped in the right hand front door upper hinge.
ESTIMATING AND ORDERING OF REPAIR PARTS
Like any other automobile repair operation, the damaged body must have a preliminary survey to determine the over all extent of the damage. When the survey has been completed, the answer to three vital questions will be nec­essary before work can begin.
Can you repair the damage? How much will it cost? How soon can it be ready?
The accuracy of your answers to these vital questions determines whether or not your shop gets the repair job and whether or not you make any profit on the job if you do get it. Guessing won't do----that way you lose repair
with which you answer those three important questions.
The service departments of all Hudson distributors and dealers are supplied with current service parts catalogues from which a listing, by PROPER NAME and PART NUMBER, of the parts required can be formulated.
From this list, which includes the proper car IDENTIFICATION NUMBER taken from the car serial number plate, the Hudson parts manager will be able to arrive at an estimate of the cost of the job, from which a definite de­cision can be made before ordering the necessary parts.
To be certain that the proper repair parts are received with the least possible delay, it is important that the fol­lowing car identification be included with each repair order.
CAR SERIAL NUMBER PAINT CODE MARKINGS *
*The paint color code is the alphabetical stamping on the right hand front door upper hinge, body half.
By supplying this information you are enabling those who make up the repair parts order to include the correct parts. Thus delays, such as would be encountered upon the receipt of the wrong parts, are eliminated, and consider­able time is saved.
BODY MANUAL 7
DESCRIPTION OF PARTS
The correct description of the parts as they are listed in the service parts catalogue is all-important, as is the loca­tion of the part on the automobile.
For example fenders, doors, windshield glass, and rocker panels should be referred to as left or right, front or rear.
ORDERING TRIM MATERIAL
The following chart on the Hudson upholstery options in relation to paint options will prove helpful when the need arises to order upholstery material.
The paint option chart is also included and will serve to clarify the alphabetical paint code stamping on the upper hinge of the right hand front door and as a cross reference guide when ordering upholstery materials. See Page 4.
CHART No. 3
Use This Chart In Conjunction With Chart No. 1, Paint Option Codes
1948 COMMODORE SERIES UPHOLSTERY OPTIONS
Option Model Upholstery Color Standard with Body Colors
W-1 W-2
482-484 482-484
Tan Broadcloth Gray Broadcloth
H,K,M,N,P,RR,S,HN,SP,RM B,CC,G,J,K,Q,JB,QG
1949 COMMODORE SERIES - EXCEPT CONVERTIBLES
W-1 W-2 W-3
W-4
492-494 492-494 492-494
492-494
Tan Broadcloth Gray Broadcloth Brown Cloth and Maroon Leather Trim Gray Cloth and Maroon Leather Trim
H,M,N,P,RR,S,HN,SP, and RM B,CC,G,J,K,Q,JB, and QG
(Optional)
(Optional)
CONVERTIBLE BROUGHAM UPHOLSTERY
Models Color
491, 492, 494 Maroon Leather antique grain is standard
Models Color
481, 491, 483, 493 Bedford Cord cloth, Blue-Green shade, is
SUPER SERIES UPHOLSTERY
standard
8 BODY MANUAL
CHART No. 4
Use this chart in conjunction with chart No. 2, 1949 "Paint Option Codes"
COMMODORE SERIES - EXCEPT CONVERTIBLES
Option Model Upholstery Color Standard with Body Colors
W-1
W-2
492-494
492-494
Tan Cloth Trim
Gray Cloth Trim
CONVERTIBLE BROUGHAM UPHOLSTERY
Models Models
491-492-494 Maroon full leather trim is standard.
Brown cloth and maroon leather combination trim - optional. Gray cloth and maroon leather combination trim - optional.
SUPER SERIES - EXCEPT CONVERTIBLES
Model Color
491, 492, 494 Gray cloth trim is standard
Gray leather trim - optional
M-6, RM-15, RR-16 and CC-17 H-3, N-7, HN-11, P-8, S-10, SP­14
B-1, G-2, J-4, Q-9, JB-12, QG-13
and K-5
LEATHER TRIM
ALL BROUGHAMS, SEDANS, BUSINESS COUPES, AND CLUB COUPES
Material Color
Russet Leather Trim
Gray Leather Trim
Maroon Leather Trim
Hudson upholstery materials are of the finest broadcloth and Bedford Cord available, however, this fact does not create immunity to spots and stains. For details on the removal of spots and stains, please refer to Page 44 of this manual under the heading "General Information on Appearance."
Standard with body colors S-10, P-8, SP-14, H-3, HN-11, M-6, RR-16, RM-15, and CC-17. Optional with body colors B-1, G-2, J-4, Q-9, JB-12, QG-13, and K-5
Standard with body colors B-1, G-2, J-4, Q-9, JB-12, QG-13, and K-13. Optional with S-10, P-8, SP-14, H-3, HN-11, M-6, RR-16, RM 15, and CC-17
Optional
CHART No. 5
BODY MANUAL 9
Bow
No.
1 2 3 4 5 6
1 2 3 4 5 6
Part
Number
Up to and
Including
Serial No.
ROOF BOW COLOR
Color
GUIDE
Part
Number
4 DOOR SEDAN
210761 210762 210763 210764 210765 210766
*Except car numbers 115221 thru 115722 inclusive
483115172
" " " " "
Black Light Gray Tan Light Blue Dark Red Pink
216220 216221 216222 215223 216224 216225
2 DOOR BROUGHAM
210761 210768 210769 210774 210775 210776
4912700
" " " " "
Black Light Gray Tan Light Blue Dark Red Pink
216220 215226 216227 216228 216229 216230
Serial No.
and upward Color
48311517*
" " " " "
4912701
" " " " "
Black Light Green Yellow Light Red Dark Green Dark Brown
Black Light Gray Cream Light Blue Dark Red Pink
COUPE AND CLUB COUPE
1 2 3 4 5 6
210751 210768 210769 212954 212955 212956
4912700
" " " " "
Black Light Gray Tan Silver Gold Dark Gray
216220 216226 210769 216231 215232 212956
4912701
"
491127
4912701
"
4912701
Black Light Gray
Silver Gold Gold
10 BODY MANUAL
BODY MANUAL 11
12 BODY MANUAL
BODY MANUAL 13
14 BODY MANUAL
BODY MANUAL 15
16 BODY MANUAL
Figure 13
BODY MANUAL 17
18 BODY MANUAL
REFERENCE
Source of
Information
Date Subject
BODY MANUAL 19
REMOVAL AND CARE OF
PARTS
With most damaged bodies, there are parts that have to be removed to facilitate the repair of the damaged sections. These parts, whether they are damaged or not, should be kept in some suitable container or storage bin to prevent further damage and eliminate the possibility of parts becoming lost.
Where severe body damage is encountered, it is best to remove body trim parts, all of which are easily removed, and store them in a clean, dry place. By approaching the actual repair job in this manner, more freedom and better visibility during the repair operation is possible. Considerable time. and patience, too, is thus saved in the aligning operation and in the effective placing of body jacks.
With the body trim parts safely stored out of the way, the possibility of burning, tearing, or soiling of upholstered parts is negligible.
8. Remove rear bumper extension at side of fender.
9. Pry off fender panel lower moulding.
10. Remove the two self tapping screws attaching rear fender panel and moulding retainers to the rocker panel.
11. Remove the 7 bolts and nuts attaching the fender panel and moulding retainers to the rocker panel.
12. Lift off rear fender. See Figure 14.
REMOVAL & INSTALLATION
PROCEDURES
REAR FENDER
REMOVAL:
1, Remove rear wheel cover and rod assembly.
2. Remove rear seat cushion and remove the end section of the rear seat back from same side from whlch fender is to be removed.
3. Remove rear quarter window garnish moulding and the valance reveal moulding.
4. Remove rear quarter inside trim panel.
5. Remove 3 Phillips head screws and two self tapping screws at door pillar post.
NOTE: On Broughams and Coupes it is neces­sary to remove the rear quarter window to allow removal of the three fender attaching screws located behind the glass. See "Quarter Window Glass Removal," Page No. 31.
FIGURE 14
INSTALLATION:
NOTE: Before installing rear fender apply a bead of Permagum No. 576, Part No. 175356 Sealer, starting from base of rear door hinge pillar and crossing quarter panel flange to frame at rear and to area at 2 as shown in Figure 15. Care must be taken to assure that the bead of sealer is unbroken and does not cross any fender attaching bolt holes.
6. Remove the spare tire from rear compartment to permit better accessibility.
7. Remove 7 screws inside rear compartment which fasten fender to rear quarter panel.
FIGURE 15
1. Align fender at door hinge pillar and install attaching screws. DO NOT TIGHTEN.
20 BODY MANUAL
2. Attach all upper bolts at quarter panel flange before attaching fender to rocker panel. DO NOT TIGHTEN.
FIGURE 16
3. Install rear fender seal flush with frame flange, raising the front end 1/8" to interfere with rocker panel filler, Figure 16, No. 1 and No. 2. Cement seal tightly and allow approximately 6" from the end of the seal to remain loose until the fender is completely installed, No. 4, Figure 16. Then cement seal securely to frame flange, No. 3, and fender. TIGHTEN ALL ATTACH­ING BOLTS AND SCREWS SECURELY.
FRONT FENDER
9. Remove moulding and 4 self-tapping screws attaching fender and moulding clips to front rocker panel.
10. Remove kick pad in the front seat compartment at the dash panel.
11. Remove the screw attaching the door opening belt weatherstrip to fender and front cowl panel.
12. Remove the 4 bolts from behind the kick pad which attach the fender to the dash panel and front hinge pillar.
13. Lift off front fender.
14. Remove all trim and useable parts from damaged fender and install on new fender.
INSTALLATION :
1. With help of an assistant, align fender at cowl panel and attach screws at kick panel opening and front door hinge pillar.
2. Attach fender to radiator baffle side shield, fender side dust shield, and radiator splash guard.
3. Reverse procedure of removal on balance of in­stallation.
NOTE: Reseal fender at cowl panel and at belt moulding with dolphinite sealer No. 2465,
REMOVAL:
1. Raise hood and disconnect headlight wires at junc­tion block on radiator support.
2. Remove headlight rim (3 Phillips head screws) and remove the headlight housing (4 screws).
3. Remove the attaching bolts from the fender and side dust shield.
4. Remove two bolts attaching fender tie panel and hood lock lower support to fender.
5. Remove the upper hood prop bolt and allow hood prop to be removed with fender side dust shield. Sup­port hood during this operation.
6. Raise car and remove front wheel.
7. Remove 3 bolts attaching fender to radiator baffle side shield.
8. Remove 3 bolts attaching fender to lower radiator splash guard.
NOTE: Front fender front extension is spot welded to the fender and will have to be removed with the fender.
Part No. 175367. If necessary to replace the weath­erstrip, proceed as follows: A. Apply a coating of rubber cement to the surfaces of the front pillar face and the belt weatherstrip. B. Press weatherstrip into position then insert and tighten attaching screws.
FRONT FENDER STONE GUARD
AND PANEL ASSEMBLY
REMOVAL:
1. Remove 4 bolts attaching stone guard and panel to front quarter dash panel under the fender, 2 bolts under rubber pad, and one located to the left of hood hinge.
2. Remove 3 Phillips head screws and speed nuts at dust shield extension rubber shield.
3. Remove the panel and stone guard.
INSTALLATION:
Reverse procedure of removal.
BODY MANUAL 21
1. Front fender ornament.
2. Hood louver (R.H.)
3. Radiator grille baffle side support (R.H.)
4. Front splash guard moulding
5. Front fender extension assembly (front R.H.)
6. Parking light assembly
7. Front bumper impact bar
8. Front bumper guard (outer R.H.)
9. Radiator grille moulding (lower R.H.)
10. Radiator grille baffle (lower R.H.
11. Radiator grille moulding ( center R. H.)
12. Radiator grille baffle (center R.H. )
13. Radiator grille moulding (upper R.H.)
14. Radiator grille baffle (upper R.H.)
15. Front bumper guard assembly (inner R.H.
16. Front bumper license guard (lower)
17. Radiator grille center bar (lower)
18. Front bumper license guard (upper)
19. Front bumper guard assembly (inner L.H.)
20. Radiator grille moulding (upper L.H.)
21. Radiator grille baffle (upper L.H.)
FIGURE 17
22. Radiator grille moulding (center L.H.)
23. Radiator grille baffle (center L.H.
24. Radiator grille moulding (lower L.H.)
25. Radiator grille baffle (lower L.H.)
26. Front bumper guard (outer L.H.)
27. Parking light assembly
28. Front fender extension assembly (front L.H.)
29. Front splash guard moulding
30. Radiator grille baffle side support (L. H.)
31. Radiator grille center bar
32. Hood louver (L.H.)
33. Hood front ornament assembly
34. Center windshield reveal moulding ( R. H.)
35. Windshield reveal moulding (R.H.)
36. Pulley housing and cable assembly ( R. H.)
37. Hood crest assembly
38. Center windshield reveal moulding (L. H.)
39. Windshield reveal moulding (L.H.
40. Pulley housing and cable assembly (L.H.)
41. Hood crest ornament.
22 BODY MANUAL
RADIATOR
REMOVAL:
1. Drain radiator and disconnect hoses.
2. Remove two sheet metal screws attaching deflector shield to fender tie panel.
3. Remove headlight wiring from retaining clips at the front of radiator.
4. Remove 4 hex head bolts attaching radiator to "U" channel and remove radiator.
INSTALLATION:
Reverse procedure of removal.
RADIATOR "U" CHANNEL WITH
RADIATOR REMOVED
REMOVAL:
1. Remove headlight junction blocks; leave wires attached.
2. Remove two attaching bolts (each side) from radiator mounting channel to fender.
3. Remove attaching bolts from mounting channel to fender tie panel.
4. Remove the bolt attaching the bottom of mounting channel to frame front cross-member. Remove channel from car.
INSTALLATION:
Reverse procedure of removal.
separately.
1. Remove complete front bumper assembly.
2. Remove three bolts at each side attaching splash guard to radiator grille panel.
3. Remove bolt at grille lower center bar and the bolt attaching center plate to right and left hand splash guard.
4. Slide splash guard out.
INSTALLATION:
Reverse procedure of removal.
RADIATOR FRONT SPLASH
GUARD AND MOULDING
REMOVAL:
1. Remove front bumper center grille guard.
2. Remove one bolt (each side) attaching front splash guard (center) to front fender and lower splash guard.
3. Remove two brass nuts and clips (each side) under fender attaching fender to splash guard moulding.
4. Remove bolt attaching splash guard to grille lower center bar and remove splash guard.
INSTALLATION:
RADIATOR GRILLE BAFFLE
(UPPER)
(Right or Left)
REMOVAL:
1. Remove center support bar moulding.
2. Remove screw at front and rear of center bar.
3. Remove one screw from under fender and one screw at grille baffle side supports. Remove baffle from car.
INSTALLATION:
Reverse procedure of removal.
RADIATOR SPLASH GUARD
(Right or Left)
REMOVAL:
NOTE: The splash guard consists of two pieces joined at center support. Either right or left side may be removed
Reverse procedure of removal.
RADIATOR GRILLE CENTER BAR
(UPPER)
REMOVAL:
1. Remove two screws and remove the center bar support moulding.
2. Remove bolts attaching grille baffles to center bar.
3. Remove two bolts attaching center bar to fender tie panel and to front splash guard.
4. Remove center support and splash guard center plate. Remove bar from car.
INSTALLATION:
Reverse procedure of removal.
FENDER AND GRILLE SIDE
SUPPORT
(Right or Left Hand)
REMOVAL:
1. Remove the screws attaching the radiator grille baffles to side and center support. Remove baffles.
2. Remove five bolts under fender attaching the side panel to fender.
3. Remove the three bolts, nuts, and shakeproof washers attaching the side support to the radiator mounting chan­nel.
4. Remove three bolts, nuts, and shake- proof washers attaching the side support to the lower front splash guard.
5. Remove the front splash guard and moulding and remove the side support from the car.
BODY MANUAL 23
INSTALLATION:
Reverse procedure of removal.
RADIATOR SPLASH GUARD
REMOVAL:
1. Remove two brass nuts and clips (each side) under fender attaching moulding to front fender lower extension.
2. Pry off moulding with a screwdriver. Use care if moulding is to be used again.
INSTALLATION:
Snap moulding into place and attach to fender in reverse procedure of removal.
ENGINE HOOD
REMOVAL:
FIGURE 18
HOOD ADJUSTMENT
1. Loosen the two bolts, ( 9 and 10), which attach the hood hinge to the cowl just enough to allow for backward or forward movement.
2. Loosen screws (7 and 8) attaching hinge arm to hood, (each side).
NOTE: Forward and backward adjustments and up and down adjustments can now be made at the rear of the hood. Up or down adjustments at the front of the hood can be made by raising or lowering the three rubber bumpers mounted on the front fender tie panel and adjusting the spring retainer bolt mounted on the hood lock upper support.
3. After all adjustments have been made, tighten all bolts and lock nuts securely.
HOOD LOCK UPPER SUPPORT
1. Raise and place prop under front of hood (1), Figure
18.
2. Remove two hood prop bolts ( 2), (one on each side). Hood props ( 3) remain attached to fender side dust shields ( 11).
3. Remove the two hood hinge bolts, (7 and 8), from each side at rear of hood.
4. With a helper, remove hood from car.
INSTALLATION:
Reverse procedure of removal and adjust at hood hinge bolts.
REMOVAL:
1. With a screwdriver remove the spring retainer bolt (2) from the attaching nut and remove retainer and spring, Figure 19.
2. Remove the four attaching nuts and washers ( 1) from lock support plate. 3. Remove the two sheet metal screws from bracket at rear of assembly and slide assembly to one side and remove.
INSTALLATION:
Reverse procedure of removal. Adjust locking spring by turning slotted retainer assembly to left or right.
24 BODY MANUAL
FIGURE 19
HOOD LOCK LOWER SUPPORT
FENDER TIE PANEL AND HOOD
LOCK LOWER SUPPORT
REMOVAL:
1. Raise hood and disconnect hood lock control wire.
2. Remove two bolts (each side) attaching fender tie panel and hood lock support to fender bracket.
3. Remove two bolts attaching the fender tie panel and hood lock support to radiator mounting channel.
4. Remove two bolts attaching fender tie panel to the front fender skirt.
5. Removing one bolt attaching hood lock support to radiator grille center support and remove the support assembly from the car.
INSTALLATION:
Reverse procedure of removal.
REMOVAL:
1. Disconnect flood lock control wire.
2. Remove 4 bolts attaching hood lock lower support to fender tie panel and remove lower support from car.
FIGURE 20
INSTALLATION:
Reverse procedure of removal. Lock hood control wire securely and apply water resistant grease to hood lock release catch.
HEADLINING
Preparatory to headlining removal, remove the follow­ing trim parts:
A Sun visors B Rear view mirror C Front dome lamp lens assembly D Upper and lower windshield garnish moulding E Windshield inside center trim bar F Windshield retainers G Windshield glass H Rear seat cushion, back rests, and center arm rest I Rear window J Rear package shelf K Rear quarter window garnish mouldings L Rear dome lamp lens assembly
NOTE: HANDS MUST BE CLEAN AT ALL TIMES WHEN WORKING ON THE INTERIOR TRIM OF A BODY.
REMOVAL:
1. Remove upholsterer's tacks from around rear window opening and rear quarter window openings and the cardboard tacking strips at the extreme rear edge of the headlining on the package shelf. Pull headlining loose from cement.
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