oil ASTON MARTIN V8 VANTAGE 2010 Workshop Manual
[x] Cancel search | Manufacturer: ASTON MARTIN, Model Year: 2010, Model line: V8 VANTAGE, Model: ASTON MARTIN V8 VANTAGE 2010Pages: 947, PDF Size: 43.21 MB
Page 535 of 947
Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-19
Dry Break Connector-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 undertra y (see Workshop Manual
procedure 01.02.MB Undertray - Centre - Renew).
6. Remove bolts (x4), subframe cross brace.
7. Remove centre exhaust mounti ng bolts (x4) (see Figure
1).
8. Loosen clamp nuts (x2), rele ase 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.
15. Position drain container to collect oil spillage.
16. Loosen unions and disconnect oil cooler pipes (x2) from
transaxle interconnecting pipes and plug pipe
connections (x4).
17. Remove drain container.
18. Disconnect transaxle breather pipe.
19. Release reservoir hose from mounting bracket (Clips x2)
(see Figure 2).
20. Remove bolt from reservoir bracket, release and remove clamp, tie reservoir aside (see Figure 3).
21. Remove nuts (x2), hydramounts to subframe mountings.
22. Position hydraulic lifter to support transaxle.
Repair Operation Time (ROT)
!
WA R N I N G
OBSERVE ALL OIL/FLUID 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.
Figure 2
Figure 3
!
!
Page 536 of 947
Manual Transmission (07.03)
Transmission (07.00)7-3-20 Workshop Manual Issue 5, January 2010
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 4).
26. Lower transaxle to approx . 420mm from fitted position
and retain on hydraulic lifter (see Figure 5). 27. Disconnect dry break quick-
fit connector from torque
tube pipe (see Figure 6).
28. Remove retaining clip from valve unit and disconnect hose.
29. Remove hose from under valve unit (see Figure 7).
Install
1. Install hose under valve unit.
2. Connect hose to valve unit and install retaining clip.
3. Connect dry break quick-fit connector to torque tube pipe.
4. Raise transaxle, install harness clip to subframe.
5. Connect transaxle breather pipe.
6. Raise transaxle to fitted position.
7. Install transaxle mounting brackets and hydramounts, install and torque tighten new bolts (x8).
8. Align hydramounts to subfra me, lower lifter, install and
torque nuts and remove lifter.
9. Position reservoir to bracket and fit clamp (bolt x1).
10. Position reservoir hose and secure clips.
11. Remove plugs, connect and torque oil cooler unions.
12. Apply thread lock to new Allen bolts.
13. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
Figure 4
WAR NI NG
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 5
!
!
Figure 6
Figure 7
!
!
Page 538 of 947
Manual Transmission (07.03)
Transmission (07.00)7-3-22 Workshop Manual Issue 5, January 2010
8. Connect vehicle battery.
Transmission Sensor Assembly-Renew-
Sportshift 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. Roadster Only - Remove centre undertray (see
Workshop Manual procedure 01.02.MB Undertray -
Centre - Renew).
6. Remove bolts (x4), 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.
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 (see Figure 2).
20. Remove bolt from reservoi r bracket, release and remove
clamp, tie reservoir aside (see Figure 3).
WAR NI NG
ALWAYS CONNECT THE BATTERY EARTH (+VE)
TERMINAL FIRST.
Repair Operation Time (ROT)
!
WAR NI NG
OBSERVE ALL OIL/FLUID 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.
Figure 2
!
!
Page 539 of 947
Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-23
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 sufficien tly to access harness to
subframe clip, release harness to subframe clip (see
Figure 4).
26. Lower transaxle to approx. 420mm from fitted position and retain on hydraulic lifter (see Figure 5).
27. Remove gear position sensor (screws x4). 28. Disconnect gear position
sensor from multiplug (see
Figure 6).
Install
1. Connect gear position sensor to multiplug .
2. Install gear position sensor (screws x4).
3. Raise transaxle, install harness clip to subframe.
4. Connect transaxle breather pipe.
5. Raise transaxle to fitted position. Install transaxle mounting brackets and hydramounts, install and torque
tighten new bolts (x8).
6. Align hydramounts to subfra me, lower lifter, install and
torque nuts. Remove lifter.
7. Position reservoir to bracket and fit clamp (bolt x1).
8. Position reservoir hose and secure clips.
9. Remove plugs, connect and torque oil cooler unions.
10. Apply thread lock to new Allen bolts.
11. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
12. Position earth lead to transaxle, install and torque tighten bolt.
13. Install shear plate, install bolts (x8), tighten bolts to correct torque.
14. Install tunnel heatshield, install bolts/washers (x4),
tighten bolts to correct torque.
15. Install centre and rear exha ust pipe assembly, align to
both catalysts. tighten clamp nuts to correct torque.
16. Install bolts (x4) into centre mounting.
17. Install subframe cross brace, install bolts (x4) and torque.
18. Install rear exhaust silencer assembly (see Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Re move for Access & Refit).
19. Roadster Only - Install centre undertray (see Workshop
Manual procedure 01.02.MB Undertray - Centre -
Renew).
20. Install road wheel(s).
21. Lower vehicle on ramp, remove securing straps.
Figure 3
Figure 4
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 5
!
!
Figure 6
!
Page 540 of 947
Manual Transmission (07.03)
Transmission (07.00)7-3-24 Workshop Manual Issue 5, January 2010
22. Connect vehicle battery.
23. Test drive vehicle.
Transmission Valve Block-Renew
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 Silencer & Bypass Valve
Assembly - Remove for Access & Refit).
5. Roadster Only - Remove centre undertray (see
Workshop Manual procedure 01.02.MB Undertray -
Centre - Renew).
6. Remove bolts (x4), 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.
15. Position drain container to collect oil spillage.
16. Loosen unions and disconnect oil cooler pipes (x2) from transaxle interconnecting pipes and plug pipe
connections (x4).
17. Remove drain container.
18. Disconnect transaxle breather pipe.
19. Release reservoir hose from mounting bracket (clips x2) (see Figure 2).
20. Remove bolt from reservoi r bracket, release and remove
clamp, tie reservoir aside (see Figure 3).
WAR NI NG
ALWAYS CONNECT THE BATTERY EARTH (+VE)
TERMINAL FIRST.
Repair Operation Time (ROT)
!
WAR NI NG
OBSERVE ALL OIL/FLUID 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.
Figure 2
!
!
Page 542 of 947
Manual Transmission (07.03)
Transmission (07.00)7-3-26 Workshop Manual Issue 5, January 2010
33. Remove bolt valve block to transaxle (see Figure 8).
34. Remove nuts (x3) securing valve block to transaxle and remove valve block from studs (see Figure 12).
Install
1. Install valve block to stud and fit nuts.
2. Install bolt valve block to transaxle.
3. Install hoses (x3) to valve block and install new clips.
4. Install pipe into valve bl ock and bolts (x2) pump to
transaxle (renew O-ring on hose).
5. Install clip pump hose to valve block.
6. Install reservoir hose to valve block and install new clip.
7. Connect multiplugs (x5) to valve block.
8. Connect dry break quick-fit connector to torque tube pipe.
9. Raise transaxle, install harness clip to subframe.
10. Connect transaxle breather pipe.
11. Raise transaxle to fitted position.
12. Install transaxle mounting brackets and hydramounts, install and torque tighten new bolts (x8).
13. Align hydramounts to subfra me, lower lifter, install and
torque nuts. Remove lifter.
14. Position reservoir to bracket and fit clamp (bolt x1).
15. Position reservoir hose and secure clips.
16. Remove plugs, connect and torque oil cooler unions.
17. Apply thread lock to new Allen bolts.
18. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
19. Position earth lead to transaxle, install and torque tighten bolt.
20. Install shear plate, install bolts (x8), tighten bolts to correct torque.
21. Install tunnel heatshield, install bolts/washers (x4), tighten bolts to correct torque.
22. Install centre and rear exhaust pipe assembly, align to both catalysts then tighten clamp nuts to correct torque.
23. Install bolts (x4) into centre mounting.
24. Install subframe cross brace, install bolts (x4) and torque. 25. Install rear exhaust silencer assembly (see Workshop
Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
26. Roadster Only - Install centre undertray (see Workshop
Manual procedure 01.02.MB Undertray - Centre -
Renew).
27. Install road wheel(s).
28. Lower vehicle on ramp, remove securing straps.
29. Connect vehicle battery.
30. Test drive vehicle.
Shifter Assembly Gasket-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp and secure with straps.
3. Remove gear position sens or (see Workshop Manual
procedure 07.03.AL Sensor - Transmission Assembly -
Sportshift - Renew).
4. Remove shifter unit fixings (bolts x6, nut x1), release from dowels (x2) and tie shifter aside (see Figure 1).
Figure 8
!
WAR NI NG
ALWAYS CONNECT THE BATTERY EARTH (+VE) TERMINAL FIRST.
Repair Operation Time (ROT)
ItemCode
Shifter Assembly Gasket-Renew 07.03.AN
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
!
Page 545 of 947
Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-29
22. Release the driveshafts from the transaxle.
Figure 7
23. Put an applicable container in position under the oil cooler matrix to collect oil.
24. Disconnect the pipes from the oil cooler matrix.
Figure 8
25. Let the oil drain into the container.
26. Install plugs to seal the pipe connections.
27. Remove the container of used oil. 28. Disconnect the breather pipe from the transaxle (refer
Figure 9).
Figure 9
29. Install sealing plugs into the open ports.
30. Remove the nut that attaches the right side transaxle mount to the rear subframe.
Figure 10
31. Remove the nut that attaches the left side transaxle mount to the rear subframe.
Figure 11
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.
Page 547 of 947
Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-31
43. Disconnect the electrical connector from the wiring
harness for the torque tube.
44. Remove the bolt that attaches the bracket for the electrical connector.
45. Move the bracket for the electrical connector away.
46. Remove the bolt that attaches the transaxle ground cable to the transaxle Automatic Shift Mechanism (ASM)
pump.
47. Disconnect the electrical connector from the ASM
pump.
48. Release the wiring harness for the ASM pump from the two clips that attach it to the transxle.
49. Identify and disconnect the five electrical connectors from the transaxle.
50. Disconnect the electrical connector from the selector
position sensor.
51. Remove the bolt that attaches the ground cable eyelet to the transaxle.
52. Put the wiring harness under the hydraulic pipe for the clutch, and move it away from the transaxle.
53. Put a transmission jack belo w the torque tube (refer to
Figure 18).
Figure 18
54. Adjust the height of the tran smission jack until it holds
the torque tube.
55. Remove the eight bolts that attach the torque tube to the transaxle.
Figure 19
56. Move the transaxle rearwards to give clearance between the torque tube and the transaxle.
57. Carefully lower the transaxle on the transmission jack to remove the transaxle from the vehicle.
Figure 20
58. Clean the mating faces of the component.
Install
1. Move the transaxle and transm ission jack into position
below the vehicle.
2. Remove the filler plug for the transaxle oil.
3. Do a level check of the transaxle oil.
4. Install and tighten the filler plug for the transaxle oil.
5. Use the transmission jack to adjust the height of the transaxle to align the transaxle with the torque tube.
6. Lower the transmission jack away from the torque tube.
7. Install and tighten the eight bolts that attach the torque tube to the transaxle.
8. Put the wiring harness for the transaxle into position.
9. Install the ground cable eyelet to the transaxle.
10. Install and tighten the bolt that attaches the ground cable eyelet to the transaxle.
11. Connect the electrical connector to the selector position sensor.
12. Connect the five electrical connectors to the transaxle.
13. Install the wiring harness for the ASM pump to the two clips that attach it to the transaxle.
14. Connect the electrical connector to the ASM pump.
15. Install the transaxle ground cable to the transaxle ASM pump.
16. Install and tighten the bolt that attaches the transaxle ground cable to the transaxle ASM pump.
17. Put the bracket for the electrical connector into position.
18. Install and tighten the bolt that attaches the bracket for the electrical connector.
WARNING
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.
WARNING
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.
Page 548 of 947
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.
Page 549 of 947
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)