2010 ASTON MARTIN V8 VANTAGE Sd card

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)

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-3
4. Remove the four bolts that attach the cross-brace to the rear subframe.
Figure 2
5. Remove the cross brace.
6. Remove the four bolts that attach the exhaust centre pipe to the rear silencer.
7. Loosen the two clamps that attach the exhaust centre pipe to the catalytic converters.
8. Move the clamps along the exhaust pipes.
9. Remove the four bolts that attach the exhaust centre pipe to the exhaust front mount.
10. Remove the exhaust centre pipe.
11. Remove the exhaust front mount.
12. Remove the four bolts that attach the floor heat shield to the body.
13. Remove the floor heatshield.
14. Remove the eight screws that attach the tunnel reinforcement plate to the body.
Figure 3
15. Remove the tunnel reinforcement plate. 16. Remove the nut that attaches the ground cable to the
body.
Figure 4
17. Move the ground cable away.
18. Put marks on the driveshaft to transaxle flanges to help align during installation.
19. Remove and discard the six bolts that attach the right
side driveshaft to the transaxle. Collect and keep the
bolt plates.

Figure 5
20. Remove and discard the six bolts that attach the left side driveshaft to the transaxle. Collect and keep the bolt
plates.
WARNING
GET THE AID OF ONE MORE PERSON WHEN YOU REMOVE THE EXHAUST CENTRE PIPE.
THE CENTRE EXHAUST PIPE IS HEAVY
Note: If necessary, turn the dr iveshaft to get access to the
six bolts.
Note: If necessary, turn the dr iveshaft to get access to the
six bolts.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-5
31. Put a transmission jack be low the transaxle (refer to
Figure 12).
Figure 12
32. Adjust the height of the tran smission jack until it holds
the transaxle.
33. Remove and discard the four bolts that attach the right
side transaxle mount bracket to the transaxle. (see
Figure 13).
Figure 13
34. Remove and discard the four bolts that attach the left side transaxle mount bracket to the transaxle.
Figure 14
35. Remove the transaxle mount assemblies.
Figure 15
36. Use an applicable strap to attach the transaxle to the transmission jack.
37. Lower the transaxle on the transmission jack by approximately 420 mm.
38. Release the wiring harness for the reverse lamp switch from the clip.
39. Release the electrical connector for the reverse lamp switch from the mount.
Figure 16
40. Disconnect the electrical connector from the reverse lamp switch.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-7
7. Connect the electrical connector to the reverse lamp switch.
8. Install the electrical connector for the reverse lamp switch into the mount.
9. Install the wiring harness for the reverse lamp switch to the clip.
10. Adjust the height of the transmission jack to lift the transaxle into the correct position.
11. Remove the strap from the transaxle and the transmission jack.
12. Install the transaxle mount assemblies.
Figure 21
13. Install and torque the four bolts that attach the left side transaxle mount bracket to the transaxle.
Figure 22
14. Install and torque the four bolts that attach the right side transaxle mount bracket to the transaxle.
Figure 23
15. Lower the transmission jack to align the transaxle mounts to the rear subframe.
16. Move the transmission jack away from the vehicle.
17. Install and tighten the nut that attaches the left side transaxle mount to the rear subframe.
18. Install and tighten the nut that attaches the right side transaxle mount to the rear subframe.
19. Remove and the sealing plugs from the transaxle and the breather pipe.
20. Connect breather pipe to the transaxle.
21. Remove and discard the sealing plugs from the oil cooler matrix and the pipes.
22. Connect and tighten the pipes to the oil cooler matrix.
23. Put the driveshafts into position on the transaxle shaft flanges. Align the marks on the flanges that you made
during removal.
24. 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.
25. 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.
26. Put the ground cable into position.
27. Install and tighten the nut that attaches the ground cable to the body.
28. Install the tunnel reinforcement plate.
29. Install and torque the eight bolts that attach the tunnel reinforcement plate to the body.
30. Install floor heatshield.
31. Install and tighten the four bolts that attach the floor heat shield 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 7-3-9
10. Remove bolts/washers (x4), tunnel heatshield to body, remove heatshield.
11. Remove bolts (x8), shear plate to body, remove shear plate.
12. Remove bolt securing earth lead to transaxle.
13. Mark drive shaft to differential flanges for assembly purposes.
14. Remove and discard Allen bolts (x12), collect plates (x6), drive shaft flanges to transaxle.
15. Position drain container to collect oil spillage.
16. Loosen unions and disconnect oil cooler pipes (x2) from
transaxle interconnecting pipe s. Plug pipe connections
(x4).
17. Remove drain container.
18. Disconnect transaxle breather pipe.
19. Release reservoir hose from mounting bracket (Clips x2).
20. Remove bolt from reservoir bracket, release and remove clamp, tie reservoir aside (see Figure 1).
21. Remove nuts (x2), hydramounts to subframe mountings.
22. Position hydraulic lift er to support transaxle.
23. Remove and discard bolts (x8, 4 each side), mounting brackets to transaxle. Remove mounting brackets with
hydramounts.
24. Release drive shafts from transaxle and position aside. 25. Lower transaxle sufficiently to access harness to
subframe clip, release harness to subframe clip (see
Figure 2).
26. Lower transaxle to approx. 420mm from fitted position and retain on hydraulic lifter (see Figure 3).
WA R N I N G
TRANSAXLE OIL CAN BE HARMFUL.
OBEY ALL TRANSAXLE OIL MANUFACTURER’S SAFETY INSTRUCTIONS WHEN YOU HANDLE COMPONENTS
THAT HAVE TOUCHED TRANSAXLE OIL.
Caution
Plug oil cooler connections to prevent ingress of dirt or moisture into the system.
Figure 1
!
Figure 2
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. GET THE AID OF ONE MORE PERSON WHEN YOU MOVE THE
TRANSAXLE. IF YOU DO NOT, PERSONAL INJURY CAN OCCUR.
Figure 3
!
!

Manual Transmission (07.03)
Transmission (07.00)7-3-12 Workshop Manual Issue 5, January 2010
33. Connect vehicle battery.
34. Bleed clutch (see Workshop Manual procedure 08.00.AE Clutch Hy draulic System - Sportshift - Bleed).
35. Test drive vehicle.
36. Raise vehicle on ramp; check transaxle and Sportshift
fluid.Complete Shifter Assembly-Renew-
Roadster Only
Removal
1. Disconnect vehicle battery.
2. Remove Gear position sensor (see Workshop Manual procedure 07.03.AL Sensor - Transmission Assembly -
Sportshift - Renew).
3. Release harness clip from shifter casing.
4. Remove and discard clips (x2) securing hoses into shifter assembly and disconnect hoses (see Figure 1).
5. Remove shifter unit (bolts x6, nut x1) and release from dowels (x2) (s ee Figure 2).
WAR NI NG
ALWAYS CONNECT THE BATTERY EARTH (+VE)
TERMINAL FIRST.
WAR NI NG
TRANSAXLE OIL CAN BE HARMFUL.
OBEY ALL TRANSAXLE OIL MANUFACTURER’S SAFETY INSTRUCTIONS WHEN YOU HANDLE COMPONENTS
THAT HAVE TOUCHED TRANSAXLE OIL.
Repair Operation Time (ROT)
ItemCode
Complete Shifter Assembly-Renew 07.03.AC
WAR NI NG
ALWAYS DISCONNECT THE BATTERY EARTH (- VE) TERMINAL FIRST.
Figure 1
WAR NI NG
TRANSAXLE OIL CAN BE HARMFUL.
OBEY ALL TRANSAXLE OIL MANUFACTURER’S SAFETY INSTRUCTIONS WHEN YO U HANDLE COMPONENTS
THAT HAVE TOUCHED TRANSAXLE OIL.
!
!

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-13
6. Remove and discard gasket (see Figure 3).
7. Remove and discard hose O-rings (x3).
Install
1. Install new O-rings to hoses.
2. Clean mating faces and install new gasket to dowels.
3. Ensure alignment of selector mechanism with shifter unit and install shifter unit.
4. Install hoses into shifter unit and install clips.
5. Install harness clip into shifter casing.
6. Install Gear position se nsor (see Workshop Manual
procedure 07.03.AL Sensor - Transmission Assembly -
Sportshift - Renew).
7. Connect vehicle battery.
8. Test drive vehicle.
9. Raise vehicle on ramp; Check transaxle and Sportshift fluid.
10. Lower vehicle on ramp.
Reservoir Tank Assembly-Renew-
Roadster Only
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew). 4. Remove clips and release reservoir hoses from valve unit
and pump (place drain tray to collect fluid) (see Figure
1).
5. Release reservoir hoses from transaxle mounting clips
(x2) (see Figure 2).
Figure 2
Figure 3
WA R N I N G
ALWAYS CONNECT THE BATTERY EARTH (+VE)
TERMINAL FIRST.
Repair Operation Time (ROT)
!
Figure 1
WA R N I N G
TRANSAXLE OIL CAN BE HARMFUL.
OBEY ALL TRANSAXLE OIL MANUFACTURER’S SAFETY INSTRUCTIONS WHEN YOU HANDLE COMPONENTS THAT HAVE TOUCHED TRANSAXLE OIL.
Figure 2
!
!

Manual Transmission (07.03)
Transmission (07.00)7-3-16 Workshop Manual Issue 5, January 2010
7. Remove clip and release from pump (place drain tray to collect fluid) (s ee Figure 3).
8. Remove HP hose from pump.
9. Remove and discard O-ring from hose.
10. Remove pump from transaxle (bolts x2).
Install
1. Install pump to transaxle.
2. Install new O-ring to HP hose. Install hose to pump.
3. Install reservoir hose to pump then install new clip (remove drain tray).
4. Connect pump multiplug.
5. Install ground eye to pump body.
6. Top-up reservoir.
7. Connect vehicle battery.
8. Lower vehicle, turn igniti on ON for 20 seconds to
activate gearbox pump. Turn ignition OFF and raise
vehicle.
9. Top-up reservoir.
10. Install rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
11. Lower vehicle on ramp.
HP Hose Kit-Renew-Roadster Only
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp and secure with straps.
3. Remove road wheel(s).
4. Remove rear exhaust silencer assembly (see Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
5. Remove centre undertray (see Workshop Manual procedure 01.02.MB Undertray - Centre - Renew).
6. Remove bolts (x4) and subframe cross brace.
7. Remove centre exhaust mounting bolts (x4) (see Figure 1).
8. Loosen clamp nuts (x2), release centre pipe from both catalysts.
9. Remove centre pipe and rear exhaust pipes as an
assembly.
10. Remove bolts/washers (x4), tunnel heatshield to body, remove heatshield.
11. Remove bolts (x8), shear plate to body, remove shear plate.
12. Remove bolt securing earth lead to transaxle.
13. Mark drive shaft to differential flanges for assembly purposes.
14. Remove and discard Allen bolts (x12), collect plates (x6), drive shaft flanges to transaxle.
WAR NI NG
TRANSAXLE OIL CAN BE HARMFUL.
OBEY ALL TRANSAXLE OIL MANUFACTURER’S SAFETY INSTRUCTIONS WHEN YOU HANDLE COMPONENTS
THAT HAVE TOUCHED TRANSAXLE OIL.
WAR NI NG
ALWAYS CONNECT THE BATTERY EARTH (+VE) TERMINAL FIRST.
Repair Operation Time (ROT)
ItemCode
HP Hose Kit-Renew-Roadster Only 07.03.AH
WAR NI NG
ALWAYS DISCONNECT THE BATTERY EARTH (- VE) TERMINAL FIRST.
WAR NI NG
WHEN YOU LIFT THE VEHICLE ON A 'TWO POST' LIFT MAKE SURE THAT YOU USE A STRAP TO HOLD THE
REAR END OF THE VEHICLE TO THE RAMP. IF YOU
DO NOT, THE VEHICLE CAN FALL OFF THE RAMP AND CAUSE PERSONAL INJURY OR DEATH.
Figure 1
!