2010 ASTON MARTIN V8 VANTAGE maintenance

May 2007 Workshop Manual 7-2-1
Transmission (07.00)
Contents
Transmission Cooling (07.02) ............................... 7-2-2Specifications.......................................................... 2-2
Maintenance ........................................................... 2-2Oil Cooler Matrix-Renew ....................................... 2-2
Manual Transmission Oil Ou tlet Hose-Renew ........ 2-3
Manual Transmission Oil Inlet Hose-Renew ........... 2-3
Manual Transmission (07.03) ................................ 7-3-1 Description ............................................................. 3-1Cooling .................................................................. 3-1
Specifications.......................................................... 3-2
Maintenance ........................................................... 3-2 Transaxle Assembly-Remove for Access/Refit .......... 3-2
Complete Sportshift Hydraulic Kit-Renew .............. 3-6
Complete Shifter Assembly-Renew-Roadster Only.. 3-9
Reservoir Tank Assembly-Renew-Roadster Only ... 3-10
Pump Inlet/Valve Body Bleed/Reservoir
Tank Hoses-Renew-Roadster Only ....................... 3-11
Hydraulic Pump Assembly-Renew
-Sportshift Only.................................................... 3-12
HP Hose Kit-Renew-Roadster Only ...................... 3-13
Dry Break Connector-Renew-Roadster Only ........ 3-15
Clutch Position Sensor-Renew
-Roadster/Sportshift Only ..................................... 3-17
Transmission Sensor Assembly
-Renew-Sportshift Only ........................................ 3-18
Transmission Valve Block-Renew ......................... 3-20
Shifter Assembly Gasket-Renew ........................... 3-23
Transaxle Assembly-Remove for Access & Refit
-Sportshift Only.................................................... 3-23
Transmission Axle Assembly-D rain/Refill............... 3-26
Transaxle Assembly-Renew .................................. 3-26
Automatic Control System (07.05) ........................ 7-5-1 Maintenance ........................................................... 5-1Paddle Shift Switch Assembly - Renew
- (Sportshift Only)................................................... 5-1
Sportshift Drive Switch-Ren ew-Sportshift Only ....... 5-1
Sportshift Neutral Switch-Renew-Sportshift Only .... 5-2
Sportshift Reverse Switch-Renew-Sportshift Only ... 5-2
Sportshift Comfort Switch-Renew-Sportshift Only ... 5-3
Sportshift Interface Box-Re new-Sportshift Only ...... 5-3
Manual Control System (07.06) ............................. 7-6-1 Maintenance ........................................................... 6-1Gearshift Assembly Mechan ism-Renew .................. 6-1
Transmission Gearshift Cable Assembly-Renew ...... 6-1
Automatic Shifting Subsystem (07.11)................. 7-11-1 Maintenance ......................................................... 11-1Transmission Control Module
-Renew-Sportshift Only ........................................ 11-1

Transmission Cooling (07.02)
Transmission (07.00)7-2-2 Workshop Manual May 2007
Transmission (07.00)
Transmission Cooling (07.02)
Specifications
Maintenance
Oil Cooler Matrix-Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer heatshield (see Workshop
Manual procedure 02.06.AG Heatshield - Exhaust
Muffler - Renew).
3. Position drain container to collect oil spillage. 4. Loosen oil cooler pipe unions (x2) (see Figure 1).
5. Remove nuts (x4) from oil cooler to rear bumper
armature.
07-02-001
Transmission Oil Cooler
Inlet Tube
Outlet Tube
Pipe Unions
Torque Figures
DescriptionNm.lb. / ft.
Cooler to subframe 8-10 6-7.5
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.
07-02-002

Manual Transmission (07.03)
Transmission (07.00)7-3-2 Workshop Manual Issue 5, January 2010
Specifications Maintenance
Transaxle Assembly - Remove for Access
and Install
Removal
1. Disconnect the battery ground cable.
2. Remove the rear undertray (refer to Workshop Manual procedure 01.02.PB - Rear Undertray).
3. Raise the vehicle and install straps to hold it to the lift (refer to Figure 1).
Figure 1
Type
Graziano AM803T transaxle with:
• Integrated Shifter Bellcrack System (Cable Operated)
• Integrated Reverse Switch
• Plate Type Limited Slip Differential
Synchronisers
Triple Cone Syncros on 1st and 2nd, double cone on all
other gears incl. reverse.
Lubrication
Pressure fed system with integrated pump driven by the
input shaft. Filter (filter is serviceable item).
Transaxle Oil
Shell Transaxle 75W/90 (very important that this is the
transaxle type, Do not use Shell Spirax 75W90)
Transaxle Quantity.
Coolant System Quantity. 4 ltr (7 pt / 4.2 US qts)
0.5 ltr (0.9 pt / 0.53 US qts)
Transaxle + Coolant
Quantity 4.5 ltr (7.9 pt / 4.6 US qts)
Gear Ratios
1st 2nd 3rd 4th 5th 6th
3.15:1 1.95:1 1.44:1 1.15:1 0.94:1 0.77:1 (upto VIN
C00525)
0.76:1 (VIN
C00526
Onwards)
Reverse
2.39:1
Differential Locking Ratio
10% Drive, 30% Coast
Torque Figures
DescriptionNm.lb. / ft.
Sump plug 49 36.5
LH Output shaft housing 10 7.5
Halfshaft 70 52
Differential Cover 35 26
Repair Operation Time (ROT)
ItemCode
Transaxle Assembly-Remove for
Access/Refit 07.03.AA
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.
WAR NI NG
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHA UST COOL BEFORE YOU
DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.

Automatic Control System (07.05)
Transmission (07.00)
Issue 4, November 2008 Workshop Manual 7-5-1
Transmission (07.00)
Automatic Control System
(07.05)
Maintenance
Paddle Shift Switch Assembly - Renew -
(Sportshift Only)
Remove
1. Remove the top and bottom shrouds from the steering column (Refer to ’Top and Bottom Shrouds for the
Steering Column - Remove and Install’, page 11-4-4).
2. Remove the screw that attaches the paddle shift switch assembly (switch assembly) to the steering column (Refer
to Figure. 1).
3. Move the paddle shift switch assembly to get access to the electrical connector.
4. Disconnect the electrical connector for the paddle shift switch assembly (see Figure 2). 5. Remove the switch assembly.
Install
1. Connect the electrical connector for the switch
assembly.
2. Put the switch assembly in position on the steering column.
3. Install the screw that attaches the switch assembly.
4. Remove the top and bottom shrouds from the steering column (Refer to ’Top and Bottom Shrouds for the
Steering Column - Remove and Install’, page 11-4-4).
5. Connect the vehicle battery.
Sportshift Drive Switc h-Renew-Sportshift
Only
Removal
1. Battery isolation switch OFF.
2. Remove upper centre panel using special tool (501 115) to hook into either one of the two centre air vents (see
Figure 1).
Repair Operation Time (ROT)
!
!
Repair Operation Time (ROT)
!

Manual Control System (07.06)
Transmission (07.00)
May 2007 Workshop Manual 7-6-1
Transmission (07.00)
Manual Control System (07.06)
Maintenance
Gearshift Assembly Mechanism-Renew
Removal
1. Remove panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console -
Renew).
2. Using tool (308 - 642), release selector cable ball joints (x2) from gear lever mechanism.
3. Remove screws (x6), securi ng gear lever mechanism to
housing.
4. Remove gearshift assembly mechanism.
5. Remove gear knob, collect gaiter.
Installation
1. Clean gearshift mechanism.
2. Lubricate gearshift mechanism with recommended grease.
3. Install gearshift mechanism, install and tighten screws
(x6).
4. Install selector cables to gearshift mechanism.
5. Install panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console - Renew).
6. Install gear lever gaiter, install gear knob.
Transmission Gearshift Cable Assembly-
Renew
Removal
1. Disconnect vehicle battery.
2. Remove panel assembly - console.
3. Using tool 308 - 642, release selector cable ball joint from gear lever mechanism.
4. Remove horseshoe clip secu ring selector to bracket.
5. Raise vehicle on ramp and secure with straps. 6. Remove road wheel(s).
7. Remove rear exhaust muffl
er (see Workshop Manual
procedure 09.00.KA Silencer and Bypass Valve
Assembly - Re move for Access and Refit
8. Remove bolts (x4), subframe cross brace.
9. Loosen clamp nuts (x2), release centre pipe from both catalysts.
10. Remove centre pipe and rear exhaust pipes as an
assembly.
11. Remove bolts (x4), centre heatshield to body, remove heatshield.
12. Remove bolts (x8), shear plate to body, remove shear plate.
13. Remove bolt securing earth lead to transaxle.
14. Mark drive shaft to differential flanges for assembly purposes.
15. Remove and discard Allen bolts (x12), collect plates (x6), drive shaft flanges to transaxle.
16. Release drive shafts from transaxle and position aside.
17. Position drain container to collect oil spillage.
18. Loosen unions and disconnect oil cooler pipes (x2) from
transaxle interconnecting pipes. Plug pipe connections
(x4).
19. Remove drain container.
20. Remove nuts (x2), hydra mounts to subframe mountings.
21. Position hydraulic lifter to support transaxle.
22. Remove and discard bolts (x8 (4 each side), mounting brackets to transaxle. Remove mounting brackets with
hydra mounts.
23. Release reverse lamp switch multiplug from bracket, disconnect multiplug.
24. Lower transaxle sufficiently and use tool (308 - 642) to release selector cable ball joint from selector lever.
25. Remove horse shoe clip securing selector cable to mounting bracket, remove selector cable assembly.
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.
WA R N I N G
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH
TRANSAXLE OIL.
Caution
Plug oil cooler connections to prevent ingress of dirt or moisture into the system.
Caution
Ensure that the service tool No. 0308 - 642 is used to
release selector cable ball joints from selector levers.

Automatic Shifting Subsystem (07.11)
Transmission (07.00)
May 2007 Workshop Manual 7-11-1
Transmission (07.00)
Automatic Shifting Subsystem
(07.11)
Maintenance
Transmission Control Module-Renew-
Sportshift Only
Removal
1. Open boot lid.
2. Disconnect vehicle battery.
3. Remove access panel (right-hand side).
4. Release strap securing punctu re repair kit from bracket
and remove.
5. Remove retention clip (b olt x1) and Transmission
Control Module from mounting bracket.
6. Release Transmission Control Module multiplug catches (x2), disconnect Transmission Control Module
multiplugs (x2) and remove.
Installation
1. Install Transmission Control Module and connect multiplugs.
2. Install Transmission Control Module to mounting bracket, secure with retention clip and bolt.
3. Install puncture repair kit to bracket and secure with strap.
4. Install access panel (right-hand side).
5. Connect vehicle battery.
6. Close the boot lid.
Repair Operation Time (ROT)

May 2007 Workshop Manual 8-1-1
Clutch (08.00)
Contents
Clutch Assembly (08.01)........................................ 8-1-2Description ............................................................. 1-2
Specifications.......................................................... 1-2
Maintenance ........................................................... 1-2 Clutch and Flywheel Assembly-Renew ................... 1-2
Slave Clutch Cylinder-Renew ................................. 1-3
Clutch Bleed Hose Assembly-Renew ...................... 1-4
Clutch Hydraulic System-Bleed-Sportshift Only ...... 1-4
Clutch Hydraulic System-Bleed .............................. 1-5
Master Cylinder to Slave Cylinder Tube
Assembly-Renew-Sportshift Only............................ 1-5

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.