2010 ASTON MARTIN V8 VANTAGE torque

Manual Transmission (07.03)
Transmission (07.00)7-3-32 Workshop Manual Issue 5, January 2010
19. Connect the electrical connector to the wiring harness for the torque tube.
20. Connect the hydraulic pipe for the clutch.
21. Adjust the height of the transmission jack to lift the transaxle into the correct position.
22. Remove the strap from the transaxle and the transmission jack.
23. Install the transaxle mount assemblies.
Figure 21
24. Install and tighten the four bolts that attach the left side transaxle mount bracket to the transaxle.
Figure 22
25. Install and tighten the four bolts that attach the right side transaxle mount bracket to the transaxle.
Figure 23
26. Remove and discard the cable tie to release the reservoir from the transaxle.
27. Put the reservoir into position on the transaxle bracket.
28. Install and tighten the two bolts that attach the reservoir to the transaxle bracket.
29. Install the reservior hose into the two clips.
30. Lower the transmission jack to align the transaxle mounts to the rear subframe.
31. Move the transmission ja ck away from the vehicle.
32. Install and tighten the nut that attaches the left side transaxle mount to the rear subframe.
33. Install and tighten the nut that attaches the right side transaxle mount to the rear subframe.
34. Remove and discard the seal ing plugs from the transaxle
and the breather pipe.
35. Connect the breather pipe to the transaxle.
36. Remove and discard the sealing plugs from the oil cooler matrix and the pipes.
37. Connect and tighten the pipes to the oil cooler matrix.
38. Put the driveshafts into position on the transaxle shaft flanges. Align the marks on the flanges that you made
during removal.
39. Install and torque the six new bolts that attach the left side driveshaft flange to the transaxle flange. If
necessary, turn the driveshaft to get access to all of the
bolts.
40. Install and torque the six new bolts that attach the right side driveshaft flange to the transaxle flange. If
necessary, turn the driveshaft to get access to all of the
bolts.
41. Put the ground cable into position.
42. Install and tighten the nut that attaches the ground cable to the body.
Note: Put the three driveshaft bolt plates in position when
you install the bolts in the step that follows.
Note: Put the three driveshaft bolt plates in position when
you install the bolts in the step that follows.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-33
43. Install the tunnel reinforcement plate.
44. Install and torque the eight bolts that attach the tunnel reinforcement plate to the body.
45. Install floor heatshield.
46. Install and tighten the four bolts that attach the floor heat shield to the body.
47. Install the exhaust front mount.
48. Clean the component mating faces.
49. Apply an applicable sealant to the component mating faces.
50. Install the exhaust centre pipe.
51. Install and tighten the four bolts that attach the exhaust centre pipe to the exhaust front mount.
52. Put the clamps into position on the exhaust pipes.
53. Loosely install the four bolts that attach the exhaust centre pipe to the rear silencer.
54. Align the exhaust assembly.
55. Tighten the two clamps that attach the exhaust centre pipe to the catalytic converters.
56. Install the cross brace.
Figure 24
57. Install and torque the four bolts that attach the cross brace to the rear subframe.
Figure 25
58. Remove the strap that attaches the vehicle to the lift.
59. Lower the vehicle until the wheels are approximately 10 mm above the ground.
60. Connect the battery ground cable.
61. Bleed the clutch system.
62. Use AMDS to do an ASM self-tune.
63. Start the engine, select first gear and allow the wheels to turn for 10 seconds.
64. Lift the vehicle.
65. Remove the fill plug for the transaxle oil.
66. Make sure that the transaxle oil is level with the opening for the transaxle oil. Add more oil if necessary.
67. Install and tighten the fill plug for the transaxle oil.
68. Do a check of the ASM fluid level.
69. Install the rear undertray (refer to Workshop Procedure 01.02.PB - Rear Undertray)
Removal
1. Position vehicle on ramp.
2. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
3. Position container to collect transaxle oil.
4. Remove transaxle drain plug and drain oil.
WA R N I N G
THE EXHAUST CENTRE PIPE IS HEAVY. GET THE AID
OF ONE MORE PERSON
TO DO THE STEP THAT FOLLOWS.
Repair Operation Time (ROT)

Manual Transmission (07.03)
Transmission (07.00)7-3-34 Workshop Manual Issue 5, January 2010
5. Loosen and disconnect oil c ooler pipes and allow oil in
the oil cooler system to drain into container.
6. Remove filler plug.
7. Discard sealing washers (x2).
Install
1. Clean drain and filler plugs.
2. Install new sealing washers to filler and drain plugs.
3. Install drain plug and tighten to correct torque.
4. Install oil cooler pipes and tighten unions to correct torque.
5. Fill transaxle with the correct grade and quantity of oil.
6. Install filler plug and tighten to the correct torque.
7. Install rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
8. Lower vehicle on ramp.
9. Road test vehicle.
10. Position vehicle on ramp.
11. Check and top-up transaxle oil level.
12. Lower vehicle on ramp.
Transaxle Assembly-Renew
Removal
1. Remove transaxle assembly (see Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual -
Remove for Access & Refit).
2. Attach slings to transaxle and connect suitable hoist.
3. With assistance, remove transaxle from lifter and position on work bench.
4. Lower hoist and remove slings.
5. Position container and drain transaxle oil. 6. Remove bolt securing oi
l cooler pipes bracket to
transaxle (see Figure 1).
7. Loosen and disconnect oi l cooler pipe unions and
remove oil cooler pipe assembly (see Fig 2).
WAR NI NG
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS
SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH TRANSAXLE OIL.
WAR NI NG
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS
SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH TRANSAXLE OIL.
WAR NI NG
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS
SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH TRANSAXLE OIL.
Repair Operation Time (ROT)
Figure 1
WAR NI NG
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH
TRANSAXLE OIL.
Figure 2
Caution
Plug oil cooler connections to prevent ingress of dirt or
moisture into the system.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-35
8. Remove reverse light switch from transaxle (see Fig, 3).
9. Remove bolts (x3) from selector cable bracket to transaxle and collect bracket (see Figure 4).
10. Remove nuts (x2) from select or levers (x2) to transaxle
(see Figure 5).
Install
1. Clean reverse light switch, oil cooler pipes, selector levers and selector cable bracket. 2. Install selector levers (x2) and install and torque tighten
nuts (x2).
3. Install selector cable bracket and install and torque tighten bolts (x3).
4. Install and torque tighten reverse light switch.
5. Install oil cooler pipe assembly.
6. Install and torque tighten oil cooler pipe unions and support bracket bolt.
7. Fill transaxle with the specified oil to the correct level.
8. Attach slings to transaxle and connect hoist.
9. With assistance, remove transaxle from workbench and position on lifter.
10. Install transaxle assembly (see Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual -
Remove for Access & Refit).
11. Install road wheel(s).
12. Test drive vehicle.
13. Raise vehicle on ramp and check transaxle oil level.
14. Lower vehicle on ramp.
Figure 3
Figure 4
Figure 5
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. TO AVOID PERSONAL INJURY OR DAMAGE TO THE TRANSAXLE, HANDLING OF THE TRANSAXLE ASSEMBLY IS A TWO
PERSON OPERATION.
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. TO AVOID PERSONAL INJURY OR DAMAGE TO THE TRANSAXLE,
HANDLING OF THE TRANSAXLE ASSEMBLY IS A TWO PERSON OPERATION.
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. TO AVOID
PERSONAL INJURY OR DAMAGE TO THE TRANSAXLE, HANDLING OF THE TRANSAXLE ASSEMBLY IS A TWO PERSON OPERATION.

Manual Control System (07.06)
Transmission (07.00)7-6-2 Workshop Manual May 2007
Installation
1. Install selector cable, connect to ball joint, install horseshoe clip.
2. Connect multiplug to reverse light switch, install multiplug in bracket.
3. Install reverse light harness clip in transaxle.
4. Install transaxle mounting brackets and hydra mounts, install and torque tighten new bolts (x8).
5. Align hydra mounts to subframe, lower lifter, install and torque tighten nuts (x2). Remove lifter.
6. Remove plugs, connect and torque oil cooler unions.
7. Apply thread lock to new Allen bolts.
8. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
9. Position earth lead to transaxle, install and torque tighten bolt.
10. Install shear plate, install bolts (x8), tighten bolts to correct torque.
11. Install centre heatshield, install bolts (x4), tighten bolts to correct torque.
12. Install centre and rear exhaust pipe assembly, align to both catalysts. tighten clamp nuts to correct torque.
13. Install subframe cross brace, install and torque tighten bolts (x4).
14. Install rear exhaust muffler (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
15. Install road wheel(s).
16. Lower vehicle on ramp, remove securing straps.
17. Position selector cable in bracket, install horseshoe clip.
18. Install selector cable ball jo int to gear lever mechanism.
19. Install panel assembly - console.
20. Connect vehicle battery.
21. Test drive vehicle.
22. Raise vehicle on ramp; Check transaxle oil level.

Clutch Assembly (08.01)
8-1-2 Workshop Manual May 2007
Clutch (08.00)
Clutch Assembly (08.01)
Description
The clutch assembly consists of a balanced flywheel, a clutch
driven plate and a clutch cover.
The clutch is a single plate, diaphragm spring type assembly.
A concentric clutch slave cylinder is mounted around the
first motion shaft in the torque tube bell housing.
The clutch master cylinder is mounted on the engine
bulkhead and is operated directly by the clutch pedal.
A hydraulic connection from the master cylinder feeds
pressurised fluid to the slave cylinder. The slave cylinder has
an extension tube and bleed nipple extending from the left
side of the bell housing for bleeding the system after any
major work.
Specifications
Maintenance
Clutch and Flywheel Assembly-Renew
08.00.AA
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
4. Remove bolts (x2) from inspection cover to lower crankcase and remove cover. 5. Install special tool SKAM14546 OT to restrain flywheel
and install and tighten bolts (x2) (see Fig. 1).
6. Remove bolts (x6) from clutch cover to flywheel (see Fig.
2).
7. Release clutch cover from dowels, remove cover and collect drive plate.
Clutch Fluid
Castrol/Girling Universal Brake and Clutch fluid.
Clutch Assembly
Clutch and flywheel are separately balanced.
Clutch Plate
Single 267mm driven plate.
Torque Figures
DescriptionNmlb/ft
Flywheel Bolts
Tighten the bolts in sequence. Loosen
the bolts and then torque, in even
stages, in the same sequence. 100 -
120
74-
88.5
Clutch Bolts
Tighten x6 equally-spaced bolts, in-
turn, to pull-down the clutch evenly.
Then torque all bolts in sequence. 65-75 48-55
Starter Motor Bolts 42.5-
57.531.5-
42.5
Repair Operation Time (ROT)
Fig. 1
Fig. 2
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supported befo re removing final bolts.



Clutch Assembly (08.01)
May 2007 Workshop Manual 8-1-3
8. Remove bolts (x8) from flywheel to crankshaft and discard bolts (see Fig. 3).
9. Remove bolts (x2) and collect special tool SKAM14546 OTC.
10. Release flywheel from dowels and remove flywheel.
Installation
1. Clean flywheel and mating face on crankshaft flange.
2. Inspect pilot bearing for wear.
3. Position flywheel and align to dowel(s) on crankshaft flange.
4. Install bolts (x8) and install special tool SKAM14546 OTC to restrain flywheel.
5. Tighten flywheel bolts in the correct sequence.
6. Clean clutch cover and drive plate.
7. Install clutch assembly on flywheel and align to dowels.
8. Install bolts (x8), insert clutch alignment tool and evenly tighten bolts to the correct torque.
9. Remove clutch alignment tool.
10. Remove bolts (x2) and collect tool.
11. Install inspection cover to crankcase and tighten bolts (x2).
12. Install torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
13. Lower vehicle on ramp.
14. Connect vehicle battery.
Slave Clutch Cylinder-Renew
08.00.AC
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access and Refit).
4. Release clips and remove bleed and supply pipes from slave cylinder.
5. Install clips in union
6. Loosen and remove pipe adaptors (x2) from slave cylinder (see Fig. 1).
7. Sportshift Only - Remove bolts (x2) securing clutch
position sensor to slave cylinder.
Fig. 3
Warning
The flywheel is heavy. Ensure the flywheel is supported
before removing.
Warning
The flywheel is heavy. Ensure the flywheel is supported
when installing.
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supporte d when installing.
Caution
The flywheel and pressure are a balanced assembly. Ensure alignment marks are aligned.

Repair Operation Time (ROT)
Warning
Always disconnect the battery earth (- ve) terminal first.
Warning
When raising the vehicle on a ‘two post’ ramp, ensure
that the rear end of the vehicle is securely strapped to
the ramp. Failure to strap the rear of the vehicle down may lead to the vehicl e falling off the ramp.
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.
Fig. 1


Clutch Assembly (08.01)
8-1-4 Workshop Manual May 2007
8. Remove bolts (x2) that secure slave cylinder to torque tube (see Fig. 2).
9. Remove slave cylinder and collect spacer.
Installation
1. Clean slave cylinder, spacer and pipe adaptors.
2. Install spacer and slave cylinder and tighten bolts (x2).
3. Sportshift Only - Install clutch position sensor to slave
cylinder and secure with bolts.
4. Install pipe adaptors (x2) in slave cylinder.
5. Install bleed and supply pipes onto slave cylinder adaptors (x2) and secure with clips.
6. Install torque tube (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access and Refit).
7. Bleed clutch (see Workshop Manual procedure 08.00.AF Clutch Hydraulic System - Bleed).
8. Lower vehicle on ramp.
9. Connect vehicle battery.
Clutch Bleed Hose Assembly-Renew
08.00.AD
Removal
1. Raise vehicle on ramp.
2. Coupe Only - Remove deflector - front floor heatshield
(see Workshop Manual proc edure 09.04.AA Heatshield
- Front Floor - Renew).
3. Roadster Only - Remove exhaust sysytem (see
Workshop Manual procedure 09.00.NB Exhaust System
- Excluding manifold/down pipes - Renew). 4.
Roadster Only - Remove grommet sealing clutch bleed
pipe to torque tube.
5. Roadster Only - Position a piece of cloth in torque tube
aperture to collect spring clip (if dropped) and fluid loss.
6. Release clip and disconnect bleed hose from slave cylinder adaptor.
7. Plug slave cylinder to prevent fluid loss.
8. Release and remove bleed pipe assembly from support bracket.
Installation
1. Clean bleed hose assembly.
2. Remove plug from slave cylinder adaptor.
3. Install bleed hose and secure with clip.
4. Install bleed hose in support bracket.
5.Roadster Only - Install grommet sealing clutch bleed
pipe to torque tube.
6. Bleed clutch (see Workshop Manual procedure 08.00.AF Clutch Hydraulic System - Bleed).
7. Roadster Only - Install exhaust sysytem (see Workshop
Manual procedure 09.00.NB Exhaust System -
Excluding manifold/down pipes - Renew).
8. Coupe Only - Install deflector - front floor heatshield
(see Workshop Manual procedure 09.04.AA Heatshield
- Front Floor - Renew).
9. Lower vehicle on ramp.
Clutch Hydraulic System-Bleed-
Sportshift Only
08.00.AE
1. Raise vehicle on ramp.
2. Install Diagnostic tool and navigate to appropriate screen.
3. Position cloth around fluid reservoir to collect any spillage.
4. Remove fluid reservoir cap, en sure fluid level is correct
in reservoir.
5. Clean area around clutch bleed nipple.
6. Remove cap from bleed nipple.
7. Position bleed container containing clean hydraulic fluid, connect hose to bleed nipple.
8. Initiate bleed procedure on Diagnostic tool.
9. Loosen bleed nipple, allow air/fluid to escape and tighten bleed nipple.
10. Repeat procedure until air free fluid emerges.
11. Disconnect bleed hose, remo ve container, install dust
cap to bleed nipple.
12. Top-up fluid reservoir.
Fig. 2Warning
Always connect the battery earth (+ve) terminal first.
Repair Operation Time (ROT)
Before proceeding with the ne xt step, position a piece of
cloth in the torque tu be aperture to collect the spring clip
if dropped.
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.

Repair Operation Time (ROT)
ItemCode
Clutch Hydraulic System-Bleed
Warning
Observe all oil/fluid manufactu rers safety instructions
when handling components th at have been in contact
with transaxle oil.