drain bolt ASTON MARTIN V8 VANTAGE 2010 Owner's Guide

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)7-3-14 Workshop Manual Issue 5, January 2010
6. Remove bolt, separate bracket clamp and remove reservoir (see Figure 3).
Install
1. Install reservoir and clamp to bracket.
2. Install reservoir hoses to valve unit and pump then install new clips (remove drain tray) (see Figure 1).
3. Install reservoir hoses to clips.
4. Top-up reservoir.
5. Connect vehicle battery.
6. Lower vehicle, turn igniti on ON for 20 seconds to
activate gearbox pump. Turn ignition OFF and raise
vehicle.
7. Top-up reservoir.
8. Install rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
9. Lower vehicle on ramp.
Pump Inlet/Valve Body Bleed/Reservoir
Ta n k H o s e s
-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).
Figure 3
Figure 1
WAR NI NG
ALWAYS CONNECT THE BATTERY EARTH (+VE) TERMINAL FIRST.
!

!
Repair Operation Time (ROT)
ItemCode
Pump Inlet/Valve Body Bleed/Reservoir
Tank Hoses-Renew 07.03.AF
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 7-3-15
5. Release reservoir hoses from transaxle mounting clips (x2) (see Figure 2).
6. Remove clips and release hoses from reservoir (see Figure 3).
Install
1. Install hoses to reservoir and fit new clips.
2. Install reservoir hoses to valve unit and pump. Fit new clips (remove drain tray).
3. Install reservoir hoses to clips.
4. Top-up reservoir.
5. Connect vehicle battery.
6. Lower vehicle, turn igniti on ON for 20 seconds to
activate gearbox pump. Turn ignition OFF and raise
vehicle.
7. Top-up reservoir.
8. Install rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
9. Lower vehicle on ramp.
Hydraulic Pump Assembly-Renew-
Sportshift Only
Removal
1. Raise vehicle on ramp.
2. Disconnect vehicle battery.
3. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
4. Disconnect pump multiplug (see Figure 1).
5. Remove ground eye from pump body (bolt x1) (see Figure 2).
6. Clamp reservoir hose.
Figure 2
Figure 3
WA R N I N G
ALWAYS CONNECT THE BATTERY EARTH (+VE)
TERMINAL FIRST.
!
!
Repair Operation Time (ROT)
!

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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
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Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-17
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) from 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.
24. Remove mounting brackets with hydramounts. 25. Release drive shafts from transaxle and position aside.
26. Lower transaxle sufficiently to access harness to
subframe clip, release harness to subframe clip (see
Figure 4).
27. Lower transaxle to approx. 420mm from fitted position and retain on hydraulic lifter (see Figure 5).
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 2
Figure 3
!
!
Figure 4
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.
Figure 5
!
!

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
!
!

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
!
!

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
!
!

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-25
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. Disconnect dry break quick-
fit connector from torque
tube pipe (see Figure 6).
28. Mark and disconnect valve-block connectors positions and disconnect multiplugs (x5) (see Figure 7)).
29. Remove and discard clip, release reservoir hose from valve unit (place drain tray to collect fluid) (see Figure 8).
30. Remove and discard clips (x3) securing hoses into valve block and disconnect hoses (see Figure 7).
31. Remove clip pump hose to valve block (see Figure 10).
32. Remove bolts (x2) pump to transaxle, move pump aside and remove pipe from valve block.
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
Figure 7
!
!

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)