maintenance ASTON MARTIN V8 VANTAGE 2010 Repair Manual

Hand Brake (06.05)
Brake Systems (06.00)6-5-2 Workshop Manual May 2007
Maintenance
RH/LH Handbrake Caliper-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s.
3. Ensure handbrake leve r is fully released.
4. Release handbrake adjustment (both sides).
5. Release inner cable eyelet from lever, compress ring clip (special tool) and remove cable (see Fig. 1).
6. Remove brake pad retaining pins and anti-rattle spring.
7. Remove pads and shims from Caliper.
8. Remove Caliper bolts (x2) and Caliper.
Installation
1. Clean pads, pins and spring .
2. Install new Caliper, secu re bolts (x2) and tighten.
3. Apply anti-seize compound to pads, pins and shims.
4. Install pads into Caliper.
5. Install retaining pins and spring to Caliper.
6. Operate lever on Caliper until pads contact disc.
7. Install cable to Caliper. 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 Lever Assembly-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. Release handbrake adjustment (both sides).
5. Remove warning light switch Lucar connection.
6. Remove handbrake lever bracket (4 x bolts).
7. Remove clevis pin and clip from lever.
Installation
1. Install cable to lever.
2. Install lever to body (bolts x4) and tighten).
3. Connect warning light switch Lucar connection.
4. Install driver's seat (see Workshop Manual procedure 01.10.AB Seat Assembly - Front - LH - Remove for
Access and Refit).
5. Adjust handbrake cable (see Workshop Manual procedure 06.05.DC Handbrake Cable Assembly -
Renew).
Handbrake Pad Set-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s.
3. Ensure handbrake lever is fully released.
4. Release handbrake adjustment (both sides).
5. Remove brake pad retaining pins and anti-rattle spring.
6. Remove pads from Caliper.
Repair Operation Time (ROT)
06-05-002
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.
Repair Operation Time (ROT)
ItemCode
Handbrake Lever Assembly-Renew 06.05.CB
Repair Operation Time (ROT)
ItemCode
Handbrake Pad Set-Renew 06.05.DB
WAR NI NG
ALWAYS USE A VACUUM BRUSH OR AQUEOUS
BRAKE CLEANER TO REMOVE BRAKE DUST. NEVER USE COMPRESSED AIR.

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.

Power Brake System (06.07)
Brake System (06.00)6-7-2 Workshop Manual May 2007
Specifications
Maintenance
Brake Booster-RHD-Renew
Removal
1. Remove brake master cylind er (see Workshop Manual
procedure 06.06.EB Brake Master Cylinder Assembly
Renew).
2. Remove oil dipstick.
3. Remove vacuum hose.
4. Disconnect multiplugs (x2).
5. Remove pedal cover.
6. Remove clevis pin and clip.
7. Remove servo securing nuts (x4).
8. Remove servo assembly.
9. Remove brake light switch.
Installation
1. Install brake light switch.
2. Install servo assembly.
3. Install servo retaining nuts (x4) (torque).
4. Install clevis pin and clip.
5. Install pedal cover.
6. Connect multiplugs (x2).
7. Install vacuum hose.
8. Install dipstick. 9. Install brake master cylinder (see Workshop Manual
procedure 06.06.EB Brake Master Cylinder Assembly
Renew).
Brake Booster-LHD-Renew
Removal
1. Move drivers seat fully rearward.
2. Remove clevis pin and clip.
3. Remove booster securing nuts (x4).
4. Remove corner cross brace.
5. Move expansion tank aside for access (bolt x1, nut x1,
hose clips x2, multiplug x1).
6. Remove vacuum hose move aside.
7. Remove bolts (x2) from clutch pipe bracket and move aside.
8. Disconnect clutch reservoir feed pipe.
9. Disconnect multiplugs (x4).
10. Disconnect brake pipes from master cylinder (move aside).
11. Remove booster assembly.
12. Split components.
13. Remove reservoir securing screw (for access to securing nut).
14. Remove master cylinder from booster (nuts x2).
15. Re-fit components.
16. Install master cylinder to booster (nuts x2).
17. Install reservoir securing screw.
Torque Figures
DescriptionNm.lb. / ft.
Brake Booster Mount 21-24 15.5-18
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Brake Booster-Renew 06.07.AC
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.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.

Anti-lock Braking System (ABS) (06.09)
Brake system (06.00)
6-9-4 Workshop ManualIssue 4, November 2008
Maintenance
ABS Modulator - Remove and Install
Remove
1. Disconnect the vehicle battery.
2. Raise the vehicle and make it safe.
3. Remove the four road wheels.
4. Remove the dust caps from the four brake caliper bleed
nipples .
5. Put a container in position under the rear left-side caliper to collect brake fluid.
6. Connect a bleed hose to rear left-side caliper.
7. Open the bleed nipple.
8. Put a container in position under the front left-side caliper to collect brake fluid.
9. Connect a bleed hose to front left-side caliper
10. Open the bleed nipple.
11. Operate the brake pedal more than 60 mm and install a pedal clamp to hold it.
12. Tighten the two bleed nipples.
13. Disconnect the two bleed hoses.
14. Remove the two fluid containers.
15. Install the two dust caps.
16. Remove the five or six screws that attach the rear half of the front left wheelarch liner.
17. Remove the self-tapping screw that attaches the rear of the wheelarch liner into the wheelarch.
18. Move the wheel arch liner to get access. 19. Disconnect the electrical connector from the modulator.
20. Put a label on each brake pipe union for the assembly
procedure.
21. Loosen and disconnect the six brake pipe unions from
the modulator. Install plugs into the modulator and the
pipe connections.
22. Remove the three M8 Torx-head screws (1) that attach the modulator mounting bracket to the body.
23. Remove the modulator.
24. Remove the three M6 Torx-head bolts that attach the modulator to the mounting bracket. Remove the
mounting bracket from the modulator.
Installation
1. Install the modulator onto the mounting bracket.
2. Install and torque the three M6 Torx-head bolts.
3. Install the modulator to the body.
4. Install and torque the three M8 Torx-head screws.
5. Remove the sealing plugs.
6. Install and torque the six brake unions to the modulator.
7. Connect the electrical connector to the modulator.
8. Put the wheel arch liner back in the correct position.
9. Install the self-tapping screw that attaches the rear of the wheelarch liner into the wheelarch.
10. Install the five or six scre ws to attach the wheel arch
liner.
11. Bleed the braking system (Refer to ’Brake Bleeding - AMDS

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)