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Hudson 480 Series, Mechanical Procedure Manual

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1

ALPHABETICAL INDEX

GROUP

PAGE

GROUP

PAGE

BRAKES - SECTION 17   

Brake Pedal - Removal   
Car Pulls to one Side    
Hand Brake Cable Adjustment   
Pedal Push Rod Adjustment    

CLUTCH - SECTION 7    
 Engaging Spring Test    
ELECTRICAL - SECTION 6   

Battery Ground Strap    
Circuit Breaker   
Direction Indicator Repair   
Generator (Shunt)   
Ignition Timing    
Mechanical Advance Curve   
Spark Plugs   
Spark Setting   
Specifications    
Vacuum Advance Curve (6 cyl  )
Vacuum Advance Curve (8 cyl  )
Voltage Regulator (Shunt)   

ENGINE - SECTION 2   

Bearing Oil Leak Detector   
Cylinder Block (6 cyl.)    
Connecting Rod Bearing Sizes   
Crankshaft End Play (6 cyl  )
Flywheel Marking   
Front Mounting    
Lubrication (6 cyl  )
Main Bearing Sizes (Fitting)
Oil Pan Tray Baffle    
Oil Pressure (6 cyl  )
Piston Change (6 cyl.)    
Piston and Rod Assembly (6 cyl.)
Rear Mounting (Tightening)    
Tappet Adjustment (6 & 8 cyl.) 
Tappets and Guides (Sizes)   
Timing Gear Oiling (6 cyl.)    
Valves and Valve Seats (6 & 8 cyl.)
Valves Guides and Springs   
Vibration Dampener (Balancing) 
Vibration Dampener (Noise)    

ENGINE TUNE-UP - SECTION 5   

Air Cleaner (Oil Bath)   
Fuel Pumps (A.C. and Carter)  
Generator (Shunt)   
Fast Idle Adjustment   
Slow Idle Adjustment   
Tappet Adjustment    
Vacuum Test   
Voltage Regulator (Shunt)   

FRONT SUSPENSION - SECTION 14

Center Steering Arm Pivot   
Center Steering Arm Seal    
Rear Curb Height   

35
36
36
35
36
24
24
20
21
23

23 & 24

21
22

20 & 21

22
22
20

20 & 21

20& 22

21

3
4
8

8 & 9

8

15
12

3

5,6,7 & 8

3
3
9

9 & 10

12
13

12 & 13

11

13 &14

14 & 15

10

10 & 11

2
2
2
2
3
3
2
2
2

33
33
33
34

FUEL SYSTEM AND EXHAUST -
   SECTION 4   

Carburetor Repair    
Exhaust Manifold Heater Tube
Fast Idle Adjustment   
Fuel Gauge (Trouble Shooting)
Fuel Pumps (A.C. and Carter)
Gasoline Tank Vent   
Intake Manifold (New Style 6 cyl.) 
Manifold Studs (6 & 8 cyl.)    
Slow Idle Adjustment   
Specifications (Changes)    
Vacuum Booster Test    

HUDSON DRIVE-MASTER -
   SECTION 10    

Conditions No. 8 & 10 Correction.
Fuse Change    
Instrument Panel Switch    
Transfer Diaphragm Cyl. - Removal.
Transfer Diaphragm Cylinder -
   Disassembly   
Transmission Switch Test
   (Correction)    

OVERDRIVE - SECTION 11    

Blocker Ring Improperly Positioned  
Dash Control Improperly Connected
Oil Seal (O.D. Control Shaft)   
Oil Seal (O.D. Mainshaft)   
Overdrive Circuit Fuse   
Solenoid Improperly Installed   
Transmission and Overdrive
   Misaligned    
Trouble Shooting (Mechanical)

PROPELLER SHAFTS - SECTION 12.
 Lubrication   
SPRINGS AND SHOCK ABSORBERS -
   SECTION 16    

Perch Type Springs    
Rear Spring Lubrication    

TRANSMISSION - SECTION 9   

Gear Ratios   
Main Drive Gear Stop Ring   

VACUMOTIVE DRIVE - SECTION 8

Adjustments 8, 10 and 12   
Clutch Power Cylinder Removal
Clutch Power Cylinder Bracket
Compensator Lever - Removal 
Cushion Point Adjustment    
Piston Valve Lever Removal    
Throttle Adjustment    
Vacumotive Drive Harness Check    
Valve Rod Adjustment   

WHEELS AND TIRES - SECTION 19 
 Tire Inflation   

16

17 & 18

19
17
18
18
19
19
19
17
16
18

29
29
29
29
30

30

29
31
32
31
31
31
31
32

31
31
33
33

34
34
34
28
28

28 & 29

25
25
26
26
27
25
27
25
28
25
36
36

Summary of Contents for 480 Series

Page 1: ......

Page 2: ...conjunction with the 480 490 Mechanical Procedure Manual For quick reference all service procedure changes and corrections in this supple ment refer to group and page numbers as set forth in your 480 490 Mechanical Procedure Manual An alphabetical index of the contents of this supplement is on the following page ...

Page 3: ... 21 3 4 8 8 9 8 15 12 3 5 6 7 8 3 3 9 9 10 12 13 12 13 11 13 14 14 15 10 10 11 2 2 2 2 3 3 2 2 2 33 33 33 34 FUEL SYSTEM AND EXHAUST SECTION 4 Carburetor Repair Exhaust Manifold Heater Tube Fast Idle Adjustment Fuel Gauge Trouble Shooting Fuel Pumps A C and Carter Gasoline Tank Vent Intake Manifold New Style 6 cyl Manifold Studs 6 8 cyl Slow Idle Adjustment Specifications Changes Vacuum Booster Te...

Page 4: ...moved for a general overhaul Paragraphs No 4 5 6 should read Start the engine and run engine at 1800 RPM Normal pres sure should be 3 1 2 to 4 1 2 pounds on the standard A C pump 3 to 4 pounds with A C combination fuel and vacuum pump and 4 to 5 pounds with Carter M 729 SZ pumps Number stamped on front face of mounting flange If pressures are lower than the above examine the fuel line for dents or...

Page 5: ...s drawn through the suction side of the pump by means of a pipe connecting to a float ing screen in the oil pan The oil is then forced up into the horizontal oil gallery for distribution to the valve tappets camshaft bearings main bearings connecting rod bearings pistons piston pins and bushings timing chain and sprockets and all other movable parts requiring lubrication Figure 10 NOTE Normaloilpr...

Page 6: ...ed on page 3 14 480 490 Procedure Manual 5 Open shut off valve A admitting air into the detector tank 6 Adjust pressure reducing valve B until air pres sure gauge H shows 25 pounds pressure 7 Open shut off valve E admitting oil under 25 pounds pressure to engine oil system an d re check gauge pressure Recheck pressure from time to time as the work progresses 8 The bearing condition is indicated by...

Page 7: ...t by hand if crankshaft can be turned by hand one complete revolution bearing to journal clearance is at least 0005 If crank shaft cannot be turned by hand bearing fit is too tight 4 If crankshaft turns too freely check for loose bearings working one bearing at a time by plac ing a piece of brass shim stock 002 thick 1 2 wide and 1 long between the bearing face and the crankshaft journal Figure 4 ...

Page 8: ...rankshaft gauge in the farthest down position with the knurled locking screw FIGURE 5 4 Place the gauge on the crankshaft journal Figure 5 and rock it slightly radially several times 5 Hold the tool firmly against the journal loosen the thumbscrew so that the center plunger butts and you can hear it click against the shaft 6 Turn the thumbscrew back and forth several times then tighten DO NOT tigh...

Page 9: ...ION No 2 and No 3 bearing caps can be reversed in error Always place punch marks on the caps and the block before removal to insure proper installation SIX CYLINDER MAIN BEARING CRANKSHAFT AND CAP BORE DIAMETERS BEARING SIZE _________ SHELL THICK NESS__ CRANK SHAFT DIAMETER CAP BORE DIAMETER Standard 0955 0952 2 4998 2 4988 2 692 2 691 001 U S 0960 0957 2 4998 2 4988 2 692 2 691 002 U S 0965 0962 ...

Page 10: ...and note reading of indicator NOTE The thrust face bearing width of the number 3 crankshaft bearing has been increased 3 16 to distribute the thrust over a greater area and improve the life of the bearing Always use Genuine Hudson Bearings Refer to your parts manual for part numbers for this new type bear ing PISTONS AND CYLINDER BLOCK PAGE 3 21 6 CYLINDER Due to an engineering change effective wi...

Page 11: ...s below the fourth ring groove at the extreme bottom of the piston at right angles to the piston pin When checking piston clearance use a 1 2 feeler gauge that will extend the length of the bore Use a 002 feeler gauge for 6 cylinder engines and a 0015 feeler gauge for 8 cylinder Place the feeler gauge directly opposite the piston skirt slot when checking piston clearance Insert the piston with a s...

Page 12: ...98 was used on all the 480 models and on 490 series up to June 13 1949 Part 300098 was superseded by Part No 301934 This later type dampener has the front face machined at an angle to facilitate the drilling opera tion on the factory special balancing machine Six cylinder engines that have been balanced on the special balancing machine may be identified by a letter B stamped on the front machined ...

Page 13: ...ate the possibility of stoppage of the oil supply to the chain due to clogging of the restricted end of the oil tube The new oil trough is supplied with oil from the camshaft front bearing thrust plate overflow The new trough is attached to the cylinder block by the same screw previously used to hold the oil pipe in place Figure 13 With the new trough installation the hole drilled for the old type...

Page 14: ...readily indicated by the a m o u n t of up and down or sideways movement of the clutch housing To tighten or remove the engine rear mounting proceed as follows 1 Remove nuts lockwashers and bolts attaching the rear mounting to No 3 cross member Figure 14 2 Place a block of wood between head of jack an d oil pan to distribute pressure and avoid damaging the oil pan FIGURE 14 3 Jack up rear end of e...

Page 15: ...lose off the venting action of the pipe and create high crankcase pressure 2 Replace the fender side dust shield and rear in spection shield Tie cord of dust boot to front suspension 3 Install front wheel lower car remove jack and fender covers 4 Connect hood prop to hood and align hood VALVES AND SEATS PAGE 3 42 The valves seat directly in the cylinder block No valve inserts are used To remove th...

Page 16: ...der head Always use a torque wrench and tighten the cap screws or stud nuts in the sequence recommended to the following torque specifications 60 65 foot lbs for both alu minum and cast iron heads 6 cylinder engines 40 45 foot pounds for all 8 cylinder engines VALVE GUIDES PAGE 3 43 Before reconditioning a valve seat it is important that the valve guides be checked for wear Valve guides that are w...

Page 17: ...des to absorb any surplus draining of the thinner FLYWHEEL MARKING PAGE 3 44 Flywheel assembly Part No 166302 which was previously specified for the 480 490 series six cylin der engines has been revised so that the timing marking which read UDC 1 6 now reads UDC 1 Figure 18 This assembly with the changed marking is now being used in production on both six and eight cylinder engines replacing Part ...

Page 18: ... Carter Part No 75 686 8 cylinder 648 S Hudson Part No 301948 Carter Part No 75 607 Pump Adjustment 6 cylinder 647S 647SA 18 64 8 cylinder 648S 14 64 Vacuum Spark Port 6 and 8 cylinder Economy step 063 diameter Middle step tapers to 0565 Power step 048 diameter diameter Length 2 59 64 Economy step 061 diameter Middle step tapers to 0565 Power step 048 diameter Length 2 59 64 Economy step 068 diame...

Page 19: ...engine RPM reaches 700 for warm climate and 800 for cold climate NOTE If fast idle adjustment is checked with the carburetor installed on the engine use para graphs 4 5 and 6 only SLOW IDLE ADJUSTMENT PAGE 4 9 1 Start engine and allow engine to warm up NOTE Check choke valve must be wide open when engine is warmed up 2 With engine up to normal operating temperature turn adjusting screws A Figure 2...

Page 20: ... plugs were released for production for all 6 cylinder engines of the 490 series about July 1 1949 This change was made to com pensate for a lean mixture resulting from mounting the carburetor in a vertical position and the revision of the distributor automatic advance curve Carburetors with the new style jets can be identified by the part number 647SA on the metal tag attached to the carburetor C...

Page 21: ...chnical Policies and Information Bulletin Number 6 dated January 14 1949 MANIFOLD STUDS PAGE 4 27 6 AND 8 CYLINDER There are two types of studs used on both 6 and 8 cylinder engines namely one type stud has ma chined threads and the other has a rolled thread Studs 170990 170991 and 170992 having a cen ter punch mark on one end have a rolled thread and this portion should be out starting the other ...

Page 22: ...t 1850 RPM 8 5 at 2000 RPM 0 at 300 RPM 1 at 335 RPM 3 at 400 RPM 10 at 1025 RPM 17 5 at 1700 RPM 0 at 300 RPM 1 at 335 RPM 3 at 400 RPM 10 at 1025 RPM 17 5 at 1700 RPM Advance must follow on a smooth curve within 1 of above values VACUUM ADVANCE DISTRIBUTOR DEGREES AND INCHES OF MERCURY 6 CYLINDER 8 CYLINDER DISTRIBTOR NO IGS 4213 1 DISTRIBUTOR NO IGS 4213A 1 DISTRIBUTOR NO IGT 4204A 1 DISTRIBUTO...

Page 23: ... is not liable to result in cracked battery cells on account of being too tight FIGURE 1 GENERATOR PAGE 6 7 A few of the late 490 series cars were equipped with a Shunt Wound generator and a Vibrating Type current voltage regulator These units can be identified as follows Generator No GDZ 6001 B stamped on the generator name plate Voltage Regu lator No VRP 6002A stamped on upper face of regulator ...

Page 24: ... distributor carries part No IGT 4204A 1 and has a figure 8 5 stamped on the breaker plate Refer to the specification section of the Electrical Section for the latest specifications SPARK SETTING PAGE 6 17 Paragraph three should read Correct spark setting is obtained with the number one cylinder at top dead center rotor facing No 1 terminal of distributor cap with distributor set in mid position i...

Page 25: ...t one lead of test lamp to yellow switch wire and ground the other lamp lead Move switch lever up and lamp should light 5 If lamp fails to light in either position switch should be replaced MECHANICAL CHECK NOTE For proper operation of direction indica tor steering wheel must be properly installed in straight ahead position on steering column FIGURE 5 1 Remove switch case cover and check canceling...

Page 26: ...cket 3 Loosen steering column bracket cap at instrument panel and remove switch wire cover 4 Remove switch case and wire assembly INSTALLATION Reverse procedure of removal Connect switch wires to harness wires of same color NOTE If direction indicator lights flash too rap idly the front indicator lamp is reversed placing the parking filament in the indicator circuit and increasing the circuit resi...

Page 27: ...ve lever 28 and then releasing Above adjustment should be made with the compensator lever in starting position pin F forward as shown in solid lines Figure 11 in the 480 490 Procedure Manual FIGURE 2 ADJUSTMENT NO 10 PAGE 8 12 Add the following note To provide a greater area of contact and more positive adjustment the cushion point adjusting screw on Vacumotive Drive and Drive Master equipped cars...

Page 28: ...nk pin and disconnect lever link from bellcrank 4 Remove piston rod pivot bolt 23 5 Remove two bolts attaching clutch unit solenoid to the clutch power unit cylinder and remove clutch unit solenoid 6 Remove pal nut nut and bolt attaching clutch power cylinder to mounting bracket and remove clutch power unit piston rod and piston valve rod and link as a complete unit for disassembly and overhaul IN...

Page 29: ...ing installation Heavy side of bushing is assembled up Also check adjustment No 13 BELLCRANK TO COUPLING LEVER ROD AND PLAY LINK REMOVAL 1 Perform operations 1 2 and 3 under valve lever removal and remove the cotter pin flat washer spring and pin attaching play link to piston rod bellcrank 2 Raise car and remove cotter pin and plain washer at clutch coupling lever and remove bellcrank to clutch co...

Page 30: ...d in the 480 490 series cars as fol lows 1 82 1 used with Drive Master and 1 65 1 used on all standard transmissions without Drive Master equipment The difference in these ratios was effected by the number of teeth in the main shaft drive gear and counter shaft cluster gear After approximately August 24 1949 the 1 65 1 ratio was discontinued in production and only the 1 82 1 ratio will be standard...

Page 31: ...t hammer for this operation SECTION 10 HUDSON DRIVE MASTER CONDITION NO 8 PAGE 10 14 Paragraph C should read Follow with Drive Master Adjustments No 3 5 and 7 in order Also check Vacumotive Drive Adjustments No 4 and 6 CONDITION NO 10 PAGE 10 14 NOISY CROSS OVER This is due to looseness in the transfer diaphragm rod ball joint See Drive Master Adjustment No 1 Page 10 11 INSTRUMENT PANEL SWITCH PAG...

Page 32: ...l cracks in the diaphragm fab ric To Install Reverse procedure of removal NOTE When assembling the diaphragm cylinder the hole in the rear cover and the depression in the front cover should both be at the bottom to insure proper locating when installing TRANSFER DIAPHRAGM CYLINDER INSTALLATION 1 Use two gaskets Part No 164973 between diaphragm mounting bracket and diaphragm housing and install dia...

Page 33: ... CONDITION NO 10 DASH CONTROL IMPROPERLY CONNECTED A Unless the overdrive dash control wire is connected to the control lever on the left side of the overdrive housing in such a manner as to move the lever all the way back when the dash control knob is pushed in the lock up switch may be held open thus disabling electrical control operation Likewise it may hold the shift rail in such a position as...

Page 34: ...d upon release of solenoid the pawl will not be withdrawn promptly from engagement but may simply drift out If the solenoid stem end has its two flats exactly facing the two solenoid flange holes it will not withdraw withdraw the pawl properly If the stem can be rotated when grasped by a pair of pliers it indi cates that the internal keying has been sheared CONDITION NO 13 IMPROPER POSITIONING 0F ...

Page 35: ...ows 3 Remove the 3 bolts attaching the center steering arm bracket 42 to the No 2 cross member Figure 16 4 Remove the center pivot nut 41 and remove the steering center arm and pivot as an assembly Add the following The needle roller bearings are a press fit and can be removed with a suitable arbor press To Install reverse procedure of removal and note the following 1 When installing new bearings ...

Page 36: ...2º positive but never over 1 2 variation right or left FIGURE 2 SECTION 16 SPRINGS SHOCK ABSORBERS AND STABILIZERS REAR SPRINGS Effective November 14 1948 production began using as an option for light scale only a Spring Perch rear spring Part No 302440 on model 491 Broughams and all Coupes This spring has rubber inserts at the ends of the long leaves as illustrated in Figure 1 Following All the s...

Page 37: ... nut lubricate linkage and recheck pedal free play HAND BRAKE LEVER AND BRAKE CABLE ADJUSTMENT PAGE 17 9 With the hand brake fully released the brake cables should permit the anchor ends of the rear brake shoes to rest on the anchor pin if not readjust as follows Pull hand brake grip two notches from full release There should be 1 8 clearance between the hand brake cable lever 5 and end of slot in...

Page 38: ...nsert the 020 feeler gauge between center of secondary shoe lining and brake drum and turn adjusting screw until feeler gauge is gripped lightly After removing the feeler gauge the retraction springs will automati cally adjust both shoes to the recommended 010 clearance between the lining and drum all around SECTION 19 WHEELS AND TIRES TIRE INFLATION PAGE 19 4 Paragraph 5 should read Keep tires in...

Page 39: ......

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