Clutch Kit

Complete removal and replacement of the clutch kit on a 2009 Aston Martin DB9, requiring transmission removal to access the clutch assembly mounted to the flywheel.

Warnings

Tools required

Parts

• Clutch kit (pressure plate, disc, and release bearing) × 1 — Use OEM Aston Martin specification or LuK RepSet
• Transmission input shaft seal × 1 — Use OEM specification
• Clutch slave cylinder (if worn or leaking) × 1 — Use OEM specification
• Transmission mounting bolts (recommended replacement) × 6 — Use OEM specification
• Propeller shaft hardware (if reuse not recommended) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Disconnect negative battery terminal and secure cable away from battery post.
3. Remove engine cover by releasing quick-release fasteners.
4. Raise vehicle on lift to working height with all four wheels off ground.
5. Remove rear wheels and set aside.
6. Remove underbody panels: locate and remove Torx fasteners securing belly pans and rear diffuser section to access transmission and exhaust.
7. Place drain pan under transmission and check for any fluid leaks to address during service.
8. Install engine support bar across engine bay or attach engine hoist to lifting eyes on cylinder heads to support engine weight during transmission removal.

Procedure

1. 1

   Remove exhaust system components
   Disconnect exhaust at the catalytic converter flanges. Remove the clamp bolts securing the exhaust system. The DB9 uses a slip-joint connection at the mid-section; support the exhaust with a jack or stands and separate the rear section from the cats. Lower and remove the rear exhaust section completely from the vehicle to provide clearance for transmission removal.
2. 2

   Disconnect propeller shaft
   Mark the propeller shaft flange alignment to the transmission output flange for reinstallation reference. Remove the bolts securing the propeller shaft/torque tube connection (verify exact count and configuration — note the DB9 uses a rear-mounted transaxle connected to the engine via a torque tube, not a conventional front-mounted gearbox). Support the propeller shaft and remove the center bearing support bracket bolts from the chassis. Carefully support and separate the torque tube assembly per factory documentation; the DB9 driveshaft is enclosed within a rigid torque tube connecting engine to rear transaxle and cannot be simply lowered — verify disassembly method against factory service procedures before proceeding. Secure the shaft out of the work area.
3. 3

   Disconnect hydraulic clutch line
   Locate the hydraulic clutch line connection at the bell housing or slave cylinder (verify against factory documentation whether this vehicle uses an external slave cylinder or a concentric slave cylinder internal to the transmission). Use a line wrench to disconnect the hydraulic line fitting. Immediately cap or plug the line and fitting to prevent fluid loss and contamination. Expect some fluid spillage; use shop towels and drain pan. Note: Locate the hydraulic clutch line connection at the bell housing or slave cylinder (verify against factory documentation whether the DB9 uses an external slave cylinder or a concentric slave cylinder internal to the transmission).
4. 4

   Disconnect electrical connections from transmission
   Disconnect all electrical connectors from the transmission bell housing area. This includes the reverse light switch connector, speed sensor connectors, and any other wiring harnesses attached to the transmission. Release any clips or brackets securing wiring to the transmission case. Label connectors if necessary for reassembly reference.
5. 5

   Remove shifter linkage or cables
   Access the shift linkage connection at the transmission. The DB9 manual transmission uses a shift linkage/cable system (verify type against factory documentation). Remove the securing clips and pins connecting the shift mechanism to the transmission selector. Disconnect the linkage and secure it away from the transmission area. Note the orientation and adjustment of all linkage components for reassembly. Note: The DB9 manual transmission uses a shift linkage/cable system; verify the exact type against factory documentation before disconnecting.
6. 6

   Support transmission with transmission jack
   Position the transmission jack under the transmission case. Adjust jack height until it makes contact with the transmission oil pan or case. Secure the transmission to the jack using chains or straps to prevent movement. The jack should support the weight but not lift the transmission yet; leave weight on the mounts.
7. 7

   Remove transmission crossmember and mounts
   Locate the rear transmission mount and crossmember assembly. Remove the bolts securing the transmission mount to the crossmember (typically 2-4 bolts from below). Remove the crossmember-to-chassis bolts (typically 4 bolts, two per side). With the transmission supported on the jack, carefully remove the crossmember from the vehicle. Inspect mount condition for replacement during reassembly.
8. 8

   Remove transmission-to-engine bell housing bolts
   CRITICAL: The DB9 uses a rear transaxle connected to the engine by a torque tube, but the clutch and flywheel are mounted at the ENGINE end (front of the torque tube), NOT at the rear transaxle. To access the clutch, the torque tube and clutch bell housing at the rear of the engine must be separated per Aston Martin factory documentation — removing the rear transaxle alone does not expose the clutch. Verify the complete factory clutch-access procedure before proceeding, as the following steps assume an incorrect conventional layout. Note the position and length of each bolt as they may not be interchangeable. Remove all bell housing bolts completely, including any upper bolts accessible from the engine bay. Verify no ground straps or brackets remain attached before attempting separation.
9. 9

   Separate and remove transmission
   Ensure engine is securely supported by the engine support bar or hoist. Verify all connections, mounts, and fasteners are disconnected from the transmission. Carefully slide the transmission rearward on the jack, keeping it level and aligned with the engine. The torque tube/clutch shaft must be separated from the clutch disc splines and pilot bearing per factory procedure; note the clutch is located at the engine end, so clutch access is achieved by separating the torque tube from the engine clutch housing rather than by sliding the rear transaxle away from the clutch. This may require 4-6 inches of rearward travel before the input shaft clears the bell housing. Once clear, carefully lower the transmission on the jack and remove from under the vehicle. This operation requires two people.
10. 10

    Remove release bearing and slave cylinder
    With the transmission removed, the concentric slave cylinder/release bearing assembly is now visible on the transmission input shaft. Remove the retaining clips or bolts securing the slave cylinder to the transmission bell housing. Slide the slave cylinder and release bearing assembly off the input shaft. Inspect for wear, leaking, or damage. If replacing, have new unit ready for installation. Clean the input shaft bearing retainer surface.
11. 11

    Remove pressure plate and clutch disc
    Install the flywheel holding tool to prevent flywheel rotation. Locate the pressure plate bolts securing the pressure plate to the flywheel (verify exact count against factory documentation). Gradually loosen the bolts in a star pattern, loosening each bolt 1-2 turns at a time to evenly release spring pressure. Once all bolts are loose, remove them completely. Support the pressure plate and clutch disc as you remove the last bolts. Carefully remove the pressure plate and clutch disc from the flywheel. Note the orientation of the clutch disc (which side faces the flywheel vs. pressure plate).
12. 12

    Inspect flywheel and related components
    Inspect the flywheel surface for heat checking, cracks, scoring, or glazing. Minor surface imperfections can be resurfaced by a machine shop; deep scoring or cracks require flywheel replacement. Check flywheel thickness against service specifications. Inspect the pilot bearing in the center of the crankshaft for roughness or wear; replace if necessary using a pilot bearing puller and installer. Clean the flywheel friction surface with brake cleaner and allow to dry. Do not use oil or grease on the friction surface.
13. 13

    Install new clutch disc and pressure plate
    Ensure the flywheel surface is clean and dry. Position the new clutch disc against the flywheel with the correct orientation (the side marked 'Flywheel Side' or with the larger hub side typically faces the transmission). Insert the clutch alignment tool through the clutch disc hub and into the pilot bearing to center the disc. Position the new pressure plate over the clutch disc, aligning the dowel pins if present. Install the pressure plate bolts hand-tight (verify exact count against factory documentation). Gradually tighten the bolts in a star pattern in three stages to the Aston Martin factory-specified torque (do not use a generic guessed value — verify the exact pressure plate bolt torque in official DB9 service documentation). Keep the alignment tool in place until all bolts are torqued. Remove the alignment tool and verify the clutch disc can move slightly but is centered.
14. 14

    Install release bearing and slave cylinder
    Install the new or inspected release bearing/concentric slave cylinder assembly onto the transmission input shaft. Ensure the bearing slides smoothly onto the input shaft bearing retainer. Secure the slave cylinder to the bell housing with the retaining clips or bolts. Verify the hydraulic fitting port is accessible and oriented correctly for line connection. Apply a small amount of high-temperature grease to the input shaft splines (not excessive; clutch disc must not be contaminated).
15. 15

    Install transmission to engine
    Apply a thin film of high-temperature grease to the transmission input shaft splines. Position the transmission on the transmission jack and raise it into position behind the engine. Carefully align the input shaft with the clutch disc splines and pilot bearing. Slowly slide the transmission forward, keeping it level and properly aligned. The input shaft must enter the pilot bearing smoothly without forcing. If resistance is felt, lower slightly and realign; do not force. Once the bell housing is flush against the engine block, install all bell housing bolts hand-tight, then torque in a star pattern to specification. Verify the transmission slides fully into position before tightening bolts; the bell housing should mate flush without gaps.
16. 16

    Install transmission mounts and crossmember
    With the transmission still supported on the jack, position the crossmember into place under the transmission mount. Install the crossmember-to-chassis bolts and torque to specification. Install the transmission mount-to-crossmember bolts and torque to specification. Verify all mount hardware is properly seated and torqued before removing the transmission jack.
17. 17

    Reconnect shifter linkage and cables
    Reconnect the shift linkage to the transmission selector mechanism. Install all pins, clips, and fasteners securing the linkage. Verify the linkage moves freely through all gears without binding. Adjust linkage if necessary to ensure proper gate selection and engagement.
18. 18

    Reconnect electrical connections
    Reconnect all electrical connectors to the transmission including reverse light switch, speed sensors, and any other wiring harnesses. Ensure all connectors are fully seated and locked. Secure wiring harnesses to the transmission case using the original clips and brackets.
19. 19

    Reconnect hydraulic clutch line
    Remove the caps or plugs from the hydraulic line and slave cylinder fitting. Connect the hydraulic line to the slave cylinder fitting using a line wrench. Torque the fitting to the Aston Martin factory specification (verify exact value in official DB9 service documentation; do not rely on a generic figure). Do not overtighten. Do not overtighten. The hydraulic system will require bleeding after installation is complete.
20. 20

    Install propeller shaft
    Position the propeller shaft into place, aligning the center bearing support bracket with the chassis mounting points. Install and torque the center bearing support bracket bolts. Align the propeller shaft flange with the transmission output flange using the alignment marks made during disassembly. Install the flange bolts (verify exact count against factory documentation) and torque to the Aston Martin factory specification in a star pattern. Verify the propeller shaft rotates freely without binding or vibration.
21. 21

    Install exhaust system
    Position the rear exhaust section into place and connect to the catalytic converters at the slip joint or flange connection. Install all exhaust clamp bolts and flange hardware. Torque exhaust fasteners to specification. Ensure exhaust system has proper clearance from chassis, driveline, and heat-sensitive components throughout its length.
22. 22

    Bleed hydraulic clutch system
    Locate the clutch hydraulic bleeder valve (typically on the slave cylinder or nearby hydraulic line). Fill the appropriate fluid reservoir (note: on the DB9 the clutch hydraulic circuit typically shares the brake fluid reservoir — verify against factory documentation) with the factory-specified DOT 4 brake fluid to the maximum level. Attach a clear hose to the bleeder valve and submerge the other end in a container of fresh brake fluid. Have an assistant slowly depress the clutch pedal fully and hold. Open the bleeder valve to release fluid and air, then close the valve before the assistant releases the pedal. Repeat this process until no air bubbles are visible in the expelled fluid. Maintain master cylinder reservoir level throughout bleeding process. Close bleeder valve and verify firm clutch pedal feel. Note: Fill the clutch master cylinder reservoir with the Aston Martin-specified DOT 4 brake fluid to the maximum level (verify exact fluid specification against factory documentation). Note: Fill the clutch master cylinder reservoir with the factory-specified brake fluid (typically DOT 4 — verify exact grade in factory documentation) to the maximum level.
23. 23

    Install underbody panels and wheels
    Reinstall all underbody panels, belly pans, and rear diffuser section, securing with all Torx fasteners. Install rear wheels and torque lug bolts to the factory-specified value (verify in service documentation) in a star pattern. Lower vehicle to ground.
24. 24

    Final checks and test operation
    Reconnect negative battery terminal. Install engine cover. Start the engine and verify no unusual noises from the clutch or transmission area. With the engine running and clutch pedal depressed, shift through all gears to verify proper engagement. Check for hydraulic leaks at the clutch line connection and slave cylinder. Verify clutch pedal feel is normal with no excessive freeplay or sponginess. Test drive the vehicle in a safe area to verify clutch engagement point, smooth operation, and proper gear selection under load. Monitor for any vibration or unusual behavior.

Reassembly

1. Reassembly follows the reverse order of disassembly with special attention to the following: flywheel holding during pressure plate installation, clutch disc orientation, proper clutch alignment tool use, transmission input shaft alignment during installation, torque specifications for all bell housing and mount fasteners, propeller shaft alignment marks, and complete hydraulic system bleeding.
2. Apply thread locker to transmission mount bolts and exhaust fasteners per manufacturer recommendation.
3. Verify all electrical connectors are fully seated and locked.
4. New transmission input shaft seal should be installed if any fluid leakage was observed during disassembly.
5. Break-in period: avoid aggressive clutch engagement and high-load situations for the first 500 miles to allow clutch friction material to properly seat.

Verification

• Clutch pedal should have smooth, consistent feel with engagement point approximately 1-2 inches from the floor (verify against pre-service baseline if available).
• No grinding, chattering, or slipping should occur during engagement in any gear.
• All gears should engage smoothly without resistance when clutch is fully depressed.
• No hydraulic fluid leaks should be present at the clutch line connection, slave cylinder, or master cylinder.
• No unusual noises (grinding, squealing, rattling) from the bell housing area with clutch engaged or disengaged.
• Test drive should confirm smooth acceleration without slipping under load, proper gear engagement, and no vibration through the driveline.
• Verify parking brake still functions correctly after propeller shaft and exhaust reinstallation.

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