Clutch Disc

Complete removal and replacement of the clutch disc on a 2009 Aston Martin DB9 with 6.0L V12, requiring transmission removal and access to the clutch assembly between engine and gearbox.

Warnings

Tools required

Parts

• Clutch disc × 1 — Use OEM specification for dual-mass flywheel compatibility
• Clutch release bearing × 1 — Replace as assembly with clutch
• Transmission input shaft seal × 1 — Recommended replacement during clutch service
• Rear main seal × 1 — Inspect and replace if showing any seepage
• Transmission mounting bolts × 1 — OEM replacement recommended for critical bell housing fasteners
• Propshaft center bearing bolts × 1 — Use new fasteners per OEM procedure

Preparation

1. Verify the vehicle is equipped with manual transmission. Touchtronic-equipped DB9 models do not have a serviceable clutch disc.
2. Place vehicle on a 4-post lift or frame-contact lift capable of supporting the vehicle with both front and rear suspension drooped. Chassis must remain stable with transmission removed.
3. Disconnect negative battery terminal and wait 10 minutes for airbag system capacitor discharge.
4. Remove engine undertray panels using Torx fasteners. Inspect for multiple panels covering transmission bell housing area and propshaft tunnel.
5. Place drain pan under transmission. While no fluid drain is required for clutch access, residual fluid in bell housing or slave cylinder may leak during removal.
6. Mark propshaft-to-differential flange orientation and propshaft-to-transmission flange orientation using paint pen or scribe marks for installation reference.
7. Install engine support fixture across engine bay or attach overhead hoist to engine lift points. Engine must be supported independently once transmission mounts are disconnected.

Procedure

1. 1

   Remove exhaust system rear section
   Working from under the vehicle, disconnect the rear exhaust section from the intermediate pipes at the slip joints or flange connections. On DB9 models, the rear muffler section is typically connected via spring-loaded band clamps or bolted flanges. Remove the exhaust hangers from the rubber isolators by compressing the hanger and sliding free. Lower the rear exhaust section and remove from vehicle to provide clearance for transmission removal. Inspect exhaust hangers for cracking and gaskets for deterioration.
2. 2

   Disconnect propshaft from differential and transmission
   Remove the propshaft center bearing support bracket fasteners (typically 2-3 bolts securing bracket to chassis crossmember). At the rear differential flange, remove the 6 bolts securing the propshaft to the differential companion flange, ensuring alignment marks made during preparation are visible. At the forward (engine-end) coupling, remove the coupling bolts securing the torque-tube driveshaft to the engine flywheel/flexplate flange (verify exact bolt count against Aston Martin service data). The DB9 driveshaft runs inside a torque tube to the rear transaxle; follow the manufacturer torque-tube removal procedure rather than a conventional propshaft-with-center-bearing method. Inspect center support bearing for play or noise andCV joints for wear. Note: The DB9 uses a torque-tube driveline connecting the front engine to the rear transaxle. Verify the actual driveline configuration against Aston Martin service documentation before proceeding; the torque tube and internal driveshaft removal differs substantially from a conventional two-piece propshaft.
   ⚠The propshaft is balanced as an assembly. Do not separate sections or disassemble CV joints unless replacing the entire propshaft.
3. 3

   Disconnect hydraulic clutch slave cylinder
   Locate the hydraulic clutch slave cylinder associated with the rear-mounted transaxle clutch housing. Verify its exact location against Aston Martin workshop documentation, as the DB9 clutch is housed at the rear transaxle rather than on a front engine bell housing. Disconnect the hydraulic line from the slave cylinder by removing the banjo bolt or quick-disconnect fitting. Immediately plug or cap the hydraulic line to prevent fluid loss and air introduction. Remove the mounting bolts securing the slave cylinder to the bell housing and carefully withdraw the cylinder and pushrod as an assembly. Inspect the slave cylinder for fluid leakage at the pushrod seal. Note: Locate the hydraulic clutch slave cylinder on the transaxle (the DB9 uses a rear-mounted Graziano 6-speed transaxle; the slave may be an external bell-housing unit or a concentric slave cylinder — verify configuration against Aston Martin service data). Disconnect the hydraulic line from the slave cylinder by removing the appropriate fitting per the service manual. Note: Locate the hydraulic clutch release mechanism. Verify whether this vehicle uses a concentric slave cylinder (CSC/hydraulic release bearing) integrated inside the bell housing around the input shaft, as fitted to the Graziano 6-speed manual, or an externally mounted slave cylinder per the applicable Aston Martin service documentation. Note: Air introduction during slave cylinder disconnection may require bleeding of the clutch hydraulic system. Verify the correct brake/clutch fluid specification and DOT grade against Aston Martin service documentation before topping off or bleeding.
4. 4

   Remove transmission crossmember and mounts
   Position the transmission jack under the transmission with the saddle centered on the transmission case. Raise the jack slightly to take the load off the transmission mounts. Remove the fasteners securing the rear transmission mount to the crossmember (typically 2-4 bolts or nuts per side). Remove the crossmember mounting bolts that secure the crossmember to the chassis (typically 4-6 bolts total). Lower and remove the crossmember. Inspect transmission mounts for cracking, separation, or fluid contamination indicating failure. Note: Remove rear transaxle mounting and support structure. Note: the DB9 locates the manual gearbox as a rear transaxle within the torque-tube driveline; verify the correct support, mounting, and removal sequence against Aston Martin service documentation, as this differs from a conventional engine-mounted transmission.
5. 5

   Disconnect electrical connectors and mechanical linkages
   Disconnect all electrical connectors from the transmission including reverse light switch, vehicle speed sensor (if equipped), and any additional transmission-mounted sensors. Label or photograph connector locations for reassembly. Disconnect the gear selector linkage from the transmission by removing the selector rod retaining clips or bolts at the transmission selector shaft. On DB9 models, the selector mechanism typically uses a ball-and-socket joint or clevis pin connection. Remove the starter motor if it obstructs transmission-to-engine bell housing bolt access (typically 2-3 bolts securing starter to bell housing).
6. 6

   Remove transmission bell housing fasteners
   With the transmission securely supported on the jack, locate all bell housing bolts securing the transmission to the engine block. Verify the exact clutch/bell housing fastener count and arrangement against Aston Martin workshop documentation for the 2009 DB9, as the clutch is mounted at the rear transaxle via a torque tube rather than to a conventional front engine bell housing. Remove all accessible bolts from beneath the vehicle, noting bolt lengths and positions. Some upper bell housing bolts may require access from above through the transmission tunnel or from the engine bay. Ensure all fasteners are removed before attempting to separate the transmission from the engine. Note: On the DB9, locate the housing fasteners per the torque-tube/transaxle configuration. Confirm the exact bolt count, lengths, and positions from Aston Martin service documentation before removal.
   ⚠Bell housing bolts are typically different lengths and may thread into aluminum engine block. Note each bolt position to prevent threading short bolts into deep holes or over-torquing into blind threads.
7. 7

   Separate and remove transmission assembly
   With all bell housing fasteners removed and transmission supported on jack, carefully slide the transmission rearward along the input shaft axis. The input shaft must disengage from the clutch disc splines and pilot bearing without binding. Maintain the transmission parallel to the engine block during withdrawal to prevent input shaft or clutch damage. Verify the DB9 driveline architecture before this step. In the torque-tube design the clutch assembly is located at the flywheel end of the engine and is driven through the torque-tube driveshaft; follow Aston Martin documentation for separating the driveshaft/clutch and removing the rear transaxle rather than sliding a gearbox directly off the clutch splines. Inspect the input shaft splines for wear, scoring, or galling.
   ⚠️Do not allow the transmission weight to hang on the input shaft. The clutch disc and pilot bearing can be damaged if the transmission tilts or binds during removal. Keep the transmission fully supported and parallel to the engine.
8. 8

   Inspect clutch assembly and flywheel
   With the transmission removed, the clutch assembly is now fully visible. Inspect the clutch pressure plate for hot spots (blue discoloration), cracks in the diaphragm fingers, or uneven wear on the friction surface. Inspect the flywheel friction surface for scoring, cracks, heat checking, or step wear. Measure flywheel runout if a dial indicator is available and compare against the Aston Martin factory maximum runout limit for the 2009 DB9 (exact value not confirmed here — obtain from manufacturer workshop documentation). Inspect the dual-mass flywheel for excessive free play by attempting to rotate the friction surface relative to the engine mounting flange; minimal movement (less than 5 degrees) is normal, but clunking or excessive play indicates flywheel failure. Check the pilot bearing in the crankshaft center for roughness or seizing by rotating with a finger. Note: Measure flywheel runout if a dial indicator is available and compare against the Aston Martin maximum runout specification for this engine. Inspect the dual-mass flywheel for excessive rotational free play between the primary and secondary masses; compare any play, roughness, or clunking against the manufacturer's DMF wear limits, as excessive play indicates flywheel failure.
9. 9

   Remove clutch pressure plate and disc
   Using a flywheel holding tool or large screwdriver inserted through pressure plate ventilation holes to lock the flywheel, loosen the pressure plate mounting bolts in a criss-cross pattern, loosening each bolt 1-2 turns at a time to gradually release spring pressure. Once all bolts are loose, remove the bolts completely and carefully lift the pressure plate assembly off the flywheel dowels. Support the clutch disc as the pressure plate is removed, as it is no longer clamped and will fall free. Remove the old clutch disc from the flywheel, noting the orientation ('flywheel side' or 'gearbox side' markings on the disc hub). Clean the flywheel friction surface with brake cleaner and inspect for damage that would require flywheel replacement or resurfacing.
   ⚠Loosen pressure plate bolts gradually and evenly. Rapid or uneven loosening can distort the pressure plate cover and cause sudden spring release.
10. 10

    Replace pilot bearing and inspect rear main seal
    Inspect the pilot bearing (or pilot bushing) in the crankshaft center bore. If roughness or wear is detected, remove the bearing using a slide hammer with internal pilot bearing puller attachment or by packing the bearing cavity with grease and using a close-fitting drift to hydraulically force the bearing out. Install a new pilot bearing using a pilot bearing installation tool or appropriately sized socket to drive the bearing squarely into the crankshaft bore until fully seated. Inspect the relevant transaxle input shaft seal area behind the clutch assembly for oil seepage. Note that on the DB9 rear-transaxle layout the engine rear main seal is at the engine end of the torque tube, not directly behind this clutch; verify component identity against Aston Martin documentation. If seepage is present, now is the time to replace the seal, as this requires flywheel removal. Note: Inspect the rear main seal (crankshaft seal behind the flywheel) for any signs of oil seepage. Note: on the DB9 the clutch is driven by the torque-tube driveshaft rather than a transmission input shaft; verify component terminology and layout against Aston Martin service data.
11. 11

    Install new clutch disc and pressure plate
    Apply a thin coat of high-temperature spline grease to the transmission input shaft splines (do not over-grease; excess will contaminate the clutch disc). Place the new clutch disc onto the flywheel with the correct orientation: the side marked 'flywheel side' or with the protruding hub damper springs facing the flywheel, and the flat side or 'gearbox side' marking facing outward toward where the transmission will mount. Insert the clutch alignment tool through the clutch disc hub and into the pilot bearing to center the disc on the flywheel. Position the new or resurfaced pressure plate over the flywheel dowel pins, aligning the pressure plate with the disc. Install all pressure plate mounting bolts finger-tight, ensuring the clutch disc remains centered on the alignment tool.
    ⚠Installing the clutch disc backward (with the hub facing the wrong direction) will prevent transmission installation or cause immediate clutch failure. Verify orientation markings before tightening pressure plate.
12. 12

    Torque pressure plate and verify clutch alignment
    Using a torque wrench and working in a criss-cross pattern, tighten the pressure plate mounting bolts gradually in three stages: first to approximately 25% of final torque, then 50%, then final specification. Torque the pressure plate mounting bolts to the Aston Martin factory specification for the 2009 DB9 (value not confirmed here — do not assume; obtain from manufacturer workshop manual before tightening). After torquing, verify that the clutch alignment tool still rotates freely and can be removed and reinstalled without resistance, confirming proper disc alignment. Remove the alignment tool only after confirming transmission input shaft will align during installation. Note: Aston Martin DB9 pressure plate bolt torque must be verified against manufacturer specification before final tightening; do not rely on an assumed value. Note: Torque the pressure plate bolts to the Aston Martin specification for this platform (value to be confirmed from factory service documentation before assembly).
13. 13

    Prepare transmission for installation
    Install a new release bearing onto the transmission input shaft bearing retainer if not already installed. Ensure the bearing slides freely on the retainer and the clutch fork or hydraulic actuator engages the bearing properly. Apply a light coat of high-temperature grease to the transmission input shaft splines if not already done. Inspect the transmission bell housing mating surface for debris, old gasket material, or damage. Clean with solvent and ensure the surface is clean and dry. Verify the transmission input shaft seal is in good condition or replace if any seepage was noted during removal.
14. 14

    Install transmission assembly
    Position the transmission on the transmission jack and raise to alignment height with the engine bell housing. Insert the clutch alignment tool back into the clutch disc and pilot bearing to verify alignment before transmission installation. Carefully slide the transmission forward, guiding the input shaft into the clutch disc splines. The input shaft must enter the clutch disc without forcing; if resistance is encountered, check alignment and rotate the transmission output shaft slightly to align splines. Once the input shaft is fully engaged and the bell housing is flush against the engine block, install all bell housing bolts finger-tight, ensuring correct bolt lengths are used in their original positions.
    ⚠Never use bell housing bolts to draw the transmission into place. If the transmission does not slide into full contact with the engine block with light pressure, the input shaft is misaligned. Remove transmission and re-center clutch disc.
15. 15

    Torque bell housing fasteners and reinstall crossmember
    Torque all transmission bell housing bolts in a criss-cross pattern, starting from the center and working outward. Bell housing / torque-tube fastener torque must be verified against Aston Martin service specification for this platform before final tightening; do not rely on an assumed range. Reinstall the transmission crossmember, positioning it onto the chassis mounting points and installing mounting bolts. Torque crossmember-to-chassis bolts to specification. Reinstall the transmission mount-to-crossmember fasteners and torque to specification. Lower the transmission jack slightly to transfer load to the mounts, then remove the jack. Note: Torque the transaxle/clutch housing fasteners to the Aston Martin factory specification for the 2009 DB9 (exact value not confirmed here — obtain from manufacturer workshop documentation before tightening). Note: Torque all transmission/transaxle housing bolts to the Aston Martin specification for this platform (value to be confirmed from factory service documentation before assembly).
16. 16

    Reconnect hydraulic slave cylinder
    Install the hydraulic clutch slave cylinder into the bell housing, ensuring the pushrod engages properly with the release bearing or clutch fork. Install the slave cylinder mounting bolts and torque to the Aston Martin specified value (verify against service documentation). Reconnect the hydraulic line to the slave cylinder using a new crush washer if a banjo bolt connection, or ensure the quick-disconnect fitting clicks fully into place. If air was introduced into the system, bleed the clutch hydraulic system according to manufacturer procedure (many DB9 models self-bleed when clutch pedal is pumped with reservoir cap open). Note: Install the slave cylinder mounting bolts and torque to the Aston Martin factory specification for the 2009 DB9 (exact value not confirmed here — obtain from manufacturer workshop documentation). Note: Install the slave cylinder (or concentric slave cylinder, as applicable) and torque the mounting fasteners to the Aston Martin specification for this platform (value to be confirmed from factory service documentation).
17. 17

    Reinstall propshaft and center bearing
    Raise the propshaft into position and align the forward CV joint with the transmission output flange, matching the alignment marks made during removal. Install the forward coupling bolts and torque to the Aston Martin specified value (verify against service documentation). Install the propshaft center bearing support bracket to the chassis crossmember and torque fasteners to specification. Align the rear propshaft flange with the differential companion flange, matching alignment marks, and install the 6 mounting bolts. Torque to the Aston Martin factory specification for the 2009 DB9 (exact value not confirmed here — obtain from manufacturer workshop documentation). Verify propshaft rotates freely without binding or excessive runout. Note: Install the forward propshaft coupling bolts and torque to the Aston Martin factory specification for the 2009 DB9 (exact value not confirmed here — obtain from manufacturer workshop documentation). Note: Torque to the Aston Martin specified value (verify against service documentation). Verify driveshaft rotates freely without binding or excessive runout. Note: Install the forward driveline coupling bolts and torque to the Aston Martin specification for this platform (value to be confirmed from factory service documentation). Note: Align the rear driveline flange with its mating flange, matching alignment marks, and install the mounting bolts. Torque to the Aston Martin specification for this platform (bolt count and torque value to be confirmed from factory service documentation).
18. 18

    Reconnect electrical connections and linkages
    Reconnect all transmission electrical connectors including reverse light switch, speed sensor, and any additional sensors, ensuring connectors click fully into place. Reconnect the gear selector linkage to the transmission selector shaft, installing retaining clips or bolts and verifying the linkage moves freely through all gears. If the starter motor was removed, reinstall it to the bell housing and torque mounting bolts to specification. Apply thread-locking compound to starter bolts if specified by manufacturer.
19. 19

    Reinstall exhaust system
    Position the rear exhaust section under the vehicle and install onto the rubber hanger isolators. Connect the exhaust flanges or slip joints to the intermediate pipes, installing new gaskets if equipped with flanges. Torque flange bolts or tighten band clamps to specification, ensuring even clamping pressure. Verify exhaust hangs freely without contact with chassis, driveshaft, or rear suspension components.
20. 20

    Reinstall undertray and final checks
    Reinstall all engine undertray panels using original Torx fasteners, ensuring panels are properly aligned and seated. Reconnect the negative battery terminal and torque to specification. Remove vehicle from lift. With engine off, depress clutch pedal multiple times to verify proper hydraulic pressure and pedal feel; pedal should have firm resistance and return fully. Check clutch hydraulic reservoir level and top off with the Aston Martin specified brake/clutch fluid (verify DOT grade against service documentation) if needed. Start engine and verify no abnormal noise from bell housing area. With engine running and clutch pedal depressed, shift through all gears to verify proper engagement and disengagement. Note: Check clutch hydraulic reservoir level and top off with the brake/clutch fluid specified by Aston Martin for this vehicle (confirm exact DOT rating and specification from factory documentation).

Reassembly

1. Torque all fasteners to manufacturer specification using a calibrated torque wrench, particularly bell housing bolts, pressure plate bolts, and propshaft flange bolts.
2. Verify clutch pedal free play is within specification (typically 10-15mm measured at pedal pad) after installation. Adjust at master cylinder pushrod or linkage if required.
3. Apply thread-locking compound to fasteners as specified by manufacturer, particularly starter motor bolts and pressure plate bolts if called out in service documentation.
4. Ensure all electrical connectors are fully seated and locked, and all ground straps are reinstalled to their original locations.
5. If any hydraulic clutch fluid was lost during slave cylinder disconnection, verify reservoir level and bleed system if soft pedal or engagement issues are present.

Verification

• With engine running and vehicle stationary, depress clutch pedal and shift into first gear. Engagement should be smooth without grinding. Release pedal slowly; vehicle should begin to move smoothly at the engagement point without shudder or chatter.
• Test drive vehicle and verify smooth clutch engagement and disengagement in all gears. Clutch should engage progressively without slipping under acceleration.
• Verify no driveline vibration during acceleration and deceleration. Vibration indicates propshaft misalignment or imbalance.
• After test drive, inspect bell housing area and hydraulic clutch line for any fluid leakage. Check transmission and engine for any oil leaks at mating surfaces.
• Verify clutch pedal returns fully and does not stick at any point in the travel. Pedal feel should be consistent and firm.
• Listen for any abnormal noise from the clutch or transmission during engagement, disengagement, and neutral operation. Rattling or grinding indicates improper installation or component failure.

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