2010 ASTON MARTIN V8 VANTAGE brake

Hand Brake (06.05)
Brake Systems (06.00)
May 2007 Workshop Manual 6-5-3
7. Remove Calipers bolts (x 4) and move Caliper aside.
Installation
1. Clean pins, springs, Caliper slide pins and pistons.
2. Retract pistons into Calipers.
3. Install Calipers and bolts (x2) to knuckles and tighten.
4. Apply anti-seize compound to pads, pins, and slide pins.
5. Install pads into Caliper.
6. Install retaining pins and springs to Caliper.
7. Operate lever on Caliper until pads contact discs.
8. Adjust handbrake cable (see Workshop Manual
procedure 06.05.DC Handbrake Cable Assembly -
Renew).
9. Install road wheel/s.
10. Lower vehicle on ramp.
Handbrake Cable Assembly-Adjust
1. Ensure handbrake is fully released.
2. Raise vehicle on ramp.
3. Check condition of handbrake cable.
4. Release handbrake cable adjustment (both sides).
5. Adjust cable equally at each Caliper to achieve 4 clicks at lever.
6. Check handbrake is not binding.
7. Lower vehicle on ramp.
8. Ensure warning light is off when handbrake lever is released.
9. Ensure for correct operation of handbrake.
Handbrake Cable Assembly-Vehicle Set-
Renew
Removal
1. Remove driver's seat (see Workshop Manual procedure
01.10.AB Seat Assembly - Front - LH - Remove for
Access and Refit).
2. Raise vehicle on ramp. 3. Remove road wheel/s.
4. Remove exhaust rear sile
ncer box (see Workshop
Manual procedure 09.00.KB Silencer and Bypass Valve
Assembly - Renew).
5. Remove rear heat shield bolts (x4) and clips (x2).
6. Release cable adjustments (both sides).
7. Remove handbrake bracket to access clevis pin and clip and disconnect from lever (see Workshop Manual
procedure 06.05.CB Handbrake Lever Assembly -
Renew).
8. Unclip cable in the cabin.
9. Remove screws (x4) from cable clips and unclip grommet from body clip (see Fig. 1).
10. Withdraw cable from body.
11. Release inner cable eyelets from Caliper levers, compress ring clip and remove cable (see Fig. 2).
Always replace handbrake pads in axle sets.
WA R N I N G
BEFORE MOVING OFF, OPERATE THE HANDBRAKE 2 OR 3 TIMES TO ENSURE THE HANDBRAKE WORKS
CORRECTLY. HANDBRAKE CALIPER PISTONS MAY REQUIRE TRAVEL TO CONTACT THE BRAKE PADS AND DISC.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
WA R N I N G
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUST SYSTEM TO COOL DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
Caution
Do Not attempt to disconne ct the handbrake cables
from the equaliser unit.
Fig. 1
Fig. 2
06-05-003
06-05-002

Hand Brake (06.05)
Brake Systems (06.00)6-5-4 Workshop Manual May 2007
12. Remove cable from subframe.
Installation
1. Install cable into body.
2. Connect cable to handbrake lever and install handbrake lever (see Workshop Manual procedure 06.05.CB
Handbrake Lever Assembly - Renew).
3. Clip cable in cabin
4. Install cable to subframe (bolts x4).
5. Install heat shield bolts (x4) and clips (x2).
6. Install exhaust rear silencer box (see Workshop Manual procedure 09.00.KB Silencer and Bypass Valve
Assembly - Renew).
7. Install cable to Calipers.
8. Install driver's seat (see Workshop Manual procedure 01.10.AB Seat Assembly - Front - LH - Remove for
Access and Refit).
9. Adjust handbrake cable (see Workshop Manual procedure 06.05.DC Handbrake Cable Assembly -
Renew).
10. Install road wheel/s.
11. Lower vehicle on ramp. Ensure that the handbrake
lever is fully released.
WAR NI NG
BEFORE MOVING OFF, OPERATE THE HANDBRAKE 2
OR 3 TIMES TO ENSURE THE HANDBRAKE WORKS CORRECTLY. HANDBRAKE CALIPER PISTONS MAY
REQUIRE TRAVEL TO CONTACT THE BRAKE PADS AND DISC.
If the handbrake pads are bind ing, a squeal will be emitted
from the rear brakes.

Brake Actuation System (06.06)
Brake System (06.00)
May 2007 Workshop Manual 6-6-1
Brake System (06.00)
Brake Actuation System (06.06)
Description
Tandem Master Cylinder
The short-stroke tandem master-cylinder controls two
separate brake circuits which are jointly activated by the
brake pedal. In the event of a major leak in one system, the
other will still function. The two systems are supplied by a
common brake fluid reservoir.
A pressure sensor attached to the master-cylinder provides
the ABS / DSC module with brake pressure information. This
information informs the system how hard the driver is
braking and is used as an aid for the ABS / DSC to achieve
accurate brake pressure control.
Brake Fluid Reservoir
The brake fluid reservoir is mo unted directly on the tandem
master cylinder and secured with a pin. Two stub pipes, on
the base of the reservoir, locate into the primary and
secondary chambers of the tandem master cylinder.
An integral fluid-level switch is incorporated in the reservoir.
If the brake fluid level is low, the brake warning lamp in the
Driver Information Module (D IM) will illuminate and ‘LOW
BRAKE FLUID’ will be displayed in the message center right.
Specifications
Oils/Greases
Brake Fluid Castrol Response Super Dot 4
Torque Figures
DescriptionNm.
Master Cylinder Mount 25 (+/- 4)
Brake Pipe Unions 17
Brake fluid reservoir securing pin 4
Pressure Sensor 35 (+/- 2)

Brake Actuation System (06.06)
Brake System (06.00)
6-6-2 Workshop Manual May 2007
Maintenance
Pedal Box Assembly - Renew
1. Remove front seat (see Workshop Manual procedure 01.10.AB Seat Assembly - Front - RH - Remove for
Access and Refit).
2. Disconnect multiplug from stop lamp switch (see Fig. 1).
3. Remove clip clevis pin from brake pedal. Collect wavy washer.
4. Remove clip clevis pin from clutch pedal.
5. Remove nuts (x2) securing clutch master cylinder to
pedal box.
6. Remove nuts (x4) securing brake booster assembly to
pedal box.
7. Release main harness clips (x2) from pedal box.
8. Remove bolts (x3) securing pedal box to bulkhead.
9. Remove pedal box assembly.
10. Remove stop lamp switch.
11. Remove and discard O-ring seal from clutch master cylinder.
Installation
1. Install new O-ring seal to clutch master cylinder.
2. Install stop lamp switch in pedal box.
3. Install pedal box assembly, install bolts (x3). Do not torque tighten at this stage.
4. Position brake booster, install and torque tighten nuts (x4).
5. Torque tighten pedal box bolts (x3).
6. Position clutch master cy linder, install and torque
tighten nuts (x2).
7. Secure main harness to pedal box with clips (x2) 8. Install brake pedal clevis pin, wavy washer and retaining
clip.
9. Install clutch pedal clevis pin, and retaining clip.
10. Connect multiplug to stop lamp switch.
11. Install front seat (see Workshop Manual procedure
01.10.AB Seat Assembly - Front - RH - Remove for
Access and Refit).
RHD-Brake Master Cylinder Assembly-
Renew
Removal
1. Remove reservoir cap.
2. Remove fluid in reservoir (syringe).
3. Position cloth to absorb spillage.
4. Disconnect level indicator multiplug.
5. Disconnect pressure sensor multiplug.
6. Remove clutch cylinder feed pipe.
7. Remove brake pipe union (x2).
8. Remove master cylinder from servo (nuts x2).
Installation
1. Install O-ring .
2. Install master cylinder to servo (nuts x 2) (torque).
3. Install clutch cylinder feed pipe.
4. Connect pressure switch multiplug.
5. Install brake pipe unions (x2 torque).
6. Connect level indicator multiplug.
Repair Operation Time (ROT)
A0606129
Repair Operation Time (ROT)
ItemCode
Brake Master Cylinder Assembly-
Renew RHD
06.06.EB
WAR NI NG
AVOID SKIN / EYE CONTACT OR INGESTION OF
BRAKE FLUID. IF SKIN OR EYES ARE SPLASHED WITH BRAKE FLUID, RINSE THE AFFECTED AREA
IMMEDIATELY WITH PLENTY OF WATER AND OBTAIN MEDICAL ATTENTION. IF BR AKE FLUID IS INGESTED,
OBTAIN IMMEDIATE MEDICAL ATTENTION.
WAR NI NG
BRAKE FLUID IS HYGROSCOPIC. IF KEPT IN OPENED
CONTAINERS IT WILL ABSORB WATER VAPOUR. USE ONLY BRAKE FLUID FROM FRESHLY OPENED
CONTAINERS WHEN TOPPING-UP THE BRAKE FLUID
RESERVOIR.
Caution
Brake fluid must not be allowed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work
by rinsing away with running water.
Place an absorbent cloth around the brake fluid reservoir filler neck to absorb any possible brake fluid spillage.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.

Brake Actuation System (06.06)
Brake System (06.00)
May 2007 Workshop Manual 6-6-3
7. Fill reservoir.
8. Bleed Brakes (see Workshop Manual procedure 06.06.AD Pad Kit - Manual Brake and Clutch Pedal -
Renew).
LHD-Brake Master Cylinder Assembly-
Renew
Removal
1. Remove corner cross brace.
2. Move expansion tank aside for access (bolt x1, nut x1, hose clips x2, multiplug x1).
3. Disconnect clutch reservoir feed pipe.
4. Disconnect multiplugs (x2).
5. Disconnect brake pipes from master cylinder (move aside).
6. Remove reservoir holding screw for access to master cylinder retaining nut.
7. Remove master cylinder from booster (nuts x2).
Installation
1. On new master cylinder - Remove reservoir holding screw for access to master cylinder retaining nut.
2. Install master cylinder to booster (nuts x2).
3. Install reservoir holding screw for access to master cylinder retaining nut.
4. Connect brake pipes to master cylinder.
5. Connect clutch reservoir feed pipe. 6. Connect multiplugs (x2).
7. Install expansion tank aside (bolt x1, nut x1, hose clips
x2, multiplug x1).
8. Install corner cross brace (torque) (only fully tighten
when vehicle on level floor).
9. Bleed Brakes (see Workshop Manual procedure 06.06.AD Pad Kit - Manual Brake and Clutch Pedal -
Renew).
10. Top-up coolant.
Clutch Master Cylinder Assembly-Renew
Removal
1. Move drivers seat fully rearward.
2. Remove clevis pin and clip.
3. Remove cylinder securing nuts (x2).
4. Remove fluid (syringe) from brake master cylinder to
below clutch level.
5. Remove corner cross brace.
6. Move expansion tank aside for access (bolt x1, nut x1, hose clips x2, multiplug x1).
7. Disconnect clutch reservoir feed pipe.
8. Disconnect clutch pipe quick fit (pull clip back) and move aside.
9. Remove cylinder assembly.
10. Remove and discard O-ring seal from master cylinder.
11. Split components
12. Remove pipe from cy linder (mark position).
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Brake Actuation System (06.06)
Brake System (06.00)
6-6-4 Workshop Manual May 2007
13. Re-fit components
14. Install pipe to cylinder.
Installation
1. Install new O-ring seal on master cylinder.
2. Install cylinder assembly.
3. Connect pipe to master cylinder (quickfit).
4. Connect clutch reservoir feed pipe.
5. Install expansion tank aside (bolt x1, nut x1, hose clips x2, multiplug x1).
6. Install corner cross brace (torque) (only fully tighten when vehicle on level floor).
7. Install cylinder retaining nuts (x2) (torque).
8. Install clevis pin and clip.
9. Bleed clutch system (see Workshop Manual procedure 08.00.AF - Clutch Hydraulic System - Bleed).
10. Top-up coolant.
RH/LH Front Caliper Hose Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove RH/LH front wheel arch liner (see Workshop
Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - RH/LH - Renew).
4. Remove bleed nipple dust caps.
5. Position bleed container, connect bleed hose to RHR/ LHR Caliper, open bleed nipples (x1).
6. Position bleed container, connect bleed hose to RHF/ LHF Caliper, open bleed nipples (x1).
7. Depress brake pedal >60 mm and secure with support. 8. Tighten RHR/LHR bleed nipple, disconnect bleed hose,
remove bleed container and fit dust cap.
9. Tighten RHF/LHF bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
10. Loosen and disconnect RH/LH front brake tube union from in line connector (see Fig. 1 - RHS shown).
11. Loosen and disconnect RH/LH front brake tube union from hose connection.
12. Release brake tube from clips (x2), remove brake tube.
Installation
1. Install brake tube, connect unions, secure brake tube in clips (x2), torque tighten unions.
2. Install RH/LH front wheel arch liner (see Workshop Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - RH/LH - Renew).
3. Remove pedal support.
4. Top-up brake fluid.
5. Bleed brake Caliper with assistance.
6. Remove bleed bottle.
7. Install bleed nipple dust caps.
8. Clean off excess fluid.
9. Top-up brake fluid.
10. Install road wheel(s)).
11. Lower vehicle on ramp.
Repair Operation Time (ROT)
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.
Fig. 1
A0606125

Brake Actuation System (06.06)
Brake System (06.00)
May 2007 Workshop Manual 6-6-5
RH/LH Rear Brake Caliper Tube
Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove bleed nipple dust caps.
4. Fit bleed bottle to RHR/LHR Caliper, open bleed nipples (x1).
5. Fit bleed bottle to RHF/LHF Caliper, open bleed nipples (x1).
6. Depress brake pedal >60 mm and secure with support.
7. Tighten RHF bleed nipple, remove bleed bottle and fit dust cap.
8. Tighten RHR/LHR bleed nipple, remove bleed bottle.
9. Remove screws (x5) securi ng LH/RH rear wheel arch
liner to body. 10. Ease wheel arch liner downwards to access brake tube
union (see Fig. 1 - RHS shown).
11. Loosen and disconnect brake tube unions from LH/RH in line connection and RH brake hose connection (see
Fig. 2- LHS shown).
12. Release brake tube from clips (x5) on subframe.
13. Manoeuvre and remove brake tube.
Installation
1. Install brake tube, connect unions (x2), secure brake tube in clips (x5). Torque tighten unions.
2. Position wheel arch liner, in stall and tighten screws (x5).
3. Remove pedal support.
4. Top-up brake fluid.
5. Bleed brake Caliper with assistance.
Repair Operation Time (ROT)

Fig. 1
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.

Fig. 2
Caution
Brake fluid must not be allo wed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work by rinsing away with running water.
A0606122
A0606123

Brake Actuation System (06.06)
Brake System (06.00)
6-6-6 Workshop Manual May 2007
6. Remove bleed bottle.
7. Fit bleed nipple dust caps.
8. Clean off excess fluid.
9. Top-up brake fluid.
10. Install road wheel/s
11. Lower vehicle on ramp.
Brake Master Cylinder to Modulator
Secondary Tube Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove LH front wheel arch liner (see Workshop Manual procedure 01.02.FB/01.02.BC Wheel Arch
Liner - Front - LH - Renew).
4. Remove bleed nipple dust caps.
5. Position bleed container, connect bleed hose to LHR Caliper, open bleed nipples (x1).
6. Position bleed container, connect bleed hose to LHF Caliper, open bleed nipples (x1).
7. Depress brake pedal >60 mm and secure with support.
8. Tighten LHR bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
9. Tighten LHF bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap. 10. Loosen and disconnect brake tube union from
modulator (see Fig. 1).
11. Loosen and disconnect brak e tube union from master
cylinder.
12. Remove brake tube.
Installation
1. Install brake tube, connect and torque tighten unions.
2. Install LH front wheel arch liner (see Workshop Manual procedure 01.02.FB/01.02.BC Wheel Arch Liner - Front
- LH - Renew).
3. Remove pedal support.
4. Top-up brake fluid.
5. Brake bleed (see Workshop Manual procedure 06.07.DD Brake Hydraulic System - Flush/Refill/Bleed).
6. Install road wheel(s)).
7. Lower vehicle on ramp.
Repair Operation Time (ROT)

Fig. 1
A0606126