Flywheel

Replace the flywheel on a 2009 Aston Martin DB9 6.0L V12 by removing the transmission, clutch assembly, and flywheel, then installing new components with proper torque specifications.

Warnings

Tools required

Parts

• Flywheel (dual-mass or solid, verify application) × 1 — Use OEM specification
• Clutch kit (pressure plate and disc) × 1 — Replace whenever flywheel is replaced
• Release bearing × 1 — Use OEM specification
• Flywheel bolts (if TTY) × 8 — Verify if bolts are torque-to-yield
• Transmission drain plug crush washer × 1 — Copper or aluminum sealing washer
• Propshaft coupling bolts (if reuse not permitted) × 6 — Check service manual for reuse specification
• Exhaust gaskets (mid-pipe to headers) × 2 — Replace if disturbed

Fluids

• Touchtronic 6-speed ZF ATF (if applicable to transmission type) — 9.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Chock front wheels.
2. Disconnect negative battery terminal and secure cable away from battery post.
3. Raise vehicle on lift to working height, ensuring proper engagement on lift points.
4. Remove engine undertray panels by removing Torx fasteners around perimeter.
5. Allow exhaust system to cool completely if vehicle was recently operated.
6. Place drain pan under transmission and drain transmission fluid by removing drain plug. Clean and install new crush washer on drain plug for reinstallation.
7. Support engine from above using engine support bar or hoist attachment to crossbeam mount points. Do not rely solely on engine mounts during transmission removal.

Procedure

1. 1

   Remove exhaust system mid-section
   Disconnect exhaust system at mid-pipe flanges behind catalytic converters. Remove the flange bolts connecting mid-section to headers (typically 3-4 bolts per side). Support mid-section with jack or exhaust hanger and remove rear hanger mounting points. Lower and remove mid-section to provide transmission clearance. Inspect gaskets and replace if damaged.
2. 2

   Remove propshaft
   Mark alignment of propshaft flanges to transmission and differential flanges for reinstallation reference. The DB9 does NOT use a conventional propshaft with a center bearing. The engine is connected to the rear-mounted transaxle via an enclosed torque tube containing the driveshaft. Follow the Aston Martin workshop manual procedure to support and detach the torque tube / rear-transaxle assembly; do not attempt to unbolt a center-bearing propshaft from a front transmission output flange, as this architecture does not exist on this platform. Note: The DB9 uses a torque tube containing the driveshaft, connecting the engine to the rear transaxle. Follow the factory procedure to detach and support the torque tube assembly; do not attempt to remove a conventional propshaft with a center bearing, as this architecture does not exist on this platform. Note: The DB9 uses a torque-tube driveshaft assembly between the engine and rear transaxle. Follow the service manual procedure for separating the torque tube/driveshaft rather than removing a conventional propshaft; mark all couplings and verify the exact fastener counts and reuse requirements before disassembly.
3. 3

   Disconnect shift linkage and electrical connections
   Locate shift linkage connection at transmission (typically rod-type linkage on this platform). Disconnect linkage by removing connecting pin or bolt and disconnecting rod from shift selector lever on transmission. Disconnect all electrical connectors from transmission including reverse light switch, speed sensors, and any additional sensors. Label connectors for reinstallation reference. Disconnect clutch hydraulic line at transmission slave cylinder or remove slave cylinder mounting bolts if external type.
   ⚠Hydraulic clutch fluid will leak when line is disconnected. Cap line or remove slave cylinder as complete unit to minimize fluid loss.
4. 4

   Remove rear transmission crossmember
   Support transmission with transmission jack positioned under transmission pan. Ensure jack is secure and transmission weight is fully supported. Remove the bolts securing transmission mount to crossmember (typically 2-4 E-Torx bolts). Remove the bolts securing crossmember to chassis rails on both sides. Carefully lower crossmember away from transmission and remove from vehicle.
5. 5

   Remove starter motor
   Locate the starter motor at the engine-to-torque-tube/bellhousing junction (verify exact position per service manual). Disconnect electrical connections at starter including main battery cable and solenoid trigger wire. Remove the 2-3 bolts securing starter to bellhousing using appropriate E-Torx socket. Carefully remove starter motor from bellhousing, maneuvering around exhaust components if necessary. Note: Locate the starter motor on the bellhousing (verify exact side/position per the service manual for this engine and vehicle configuration).
6. 6

   Remove bellhousing-to-engine bolts
   Locate and remove all bellhousing-to-engine block bolts. On the DB9 the engine connects to the rear transaxle via a torque tube; verify the exact fastener count and method for separating the torque tube/bellhousing joint per the Aston Martin service manual rather than assuming a conventional bellhousing bolt pattern. Access points are limited; use E-Torx sockets with extensions and universal joints as needed. Top bolts may require access from above engine bay. Remove all bolts completely and store in organized manner for reinstallation. Note: The number of engine-side housing/torque-tube bolts must be confirmed from the Aston Martin service manual (count not yet verified for this platform).
7. 7

   Remove transmission assembly
   Verify all connections, bolts, and supports are disconnected from transmission. Ensure transmission jack is securely positioned and transmission weight is fully supported. Do NOT attempt to slide a transmission off the rear of the engine — the DB9 transaxle is rear-mounted at the differential and joined to the engine by a torque tube. Per the Aston Martin workshop manual, support and detach the torque tube / rear-transaxle assembly as a unit using equipment rated for the full assembly weight. The clutch and flywheel are accessed at the engine (front) end of the torque tube once the assembly is separated. This requires two technicians or properly positioned jack for the weight and size of the unit.
8. 8

   Remove clutch pressure plate and disc
   With flywheel now exposed, inspect clutch assembly for wear and contamination. Mark pressure plate position relative to flywheel for balance reference if reusing. Gradually loosen the 6 pressure plate bolts in star pattern, turning each bolt 1-2 turns at a time to prevent warping pressure plate. Once all tension is released, remove bolts completely. Remove pressure plate and clutch disc as assembly. Inspect release bearing on input shaft housing and replace as needed.
9. 9

   Lock crankshaft and remove flywheel bolts
   Install flywheel holding tool or insert locking tool into ring gear teeth to prevent crankshaft rotation. The flywheel is secured with a number of bolts specified by the service manual (commonly 8 on this V12, but verify the exact count before proceeding). Using appropriate E-Torx socket, loosen each bolt in star pattern gradually to prevent distortion. Remove all 8 flywheel bolts completely. Inspect bolts for stretching or damage; if bolts are torque-to-yield specification, they must be replaced and cannot be reused. Note: The flywheel is secured by a number of bolts per the service manual (count to be verified); remove each in a star pattern. Note: The flywheel is secured by a number of perimeter bolts that must be confirmed from the Aston Martin service manual before disassembly (count not yet verified). Note: These bolts MAY be torque-to-yield (torque-plus-angle); verify against the Aston Martin workshop manual before reuse. If TTY is confirmed, apply the specified initial torque followed by the specified rotation angle and always use new bolts; if a fixed torque value is specified, use that value. Do not assume TTY without manual verification.
10. 10

    Remove flywheel
    Carefully remove flywheel from crankshaft flange. Flywheel is located by dowel pins and may require gentle persuasion with plastic mallet or pry bar. Note dowel pin locations and flywheel orientation if asymmetric. On dual-mass flywheels, handle carefully as internal components can shift. Remove flywheel from engine bay. Inspect crankshaft flange surface for damage, scoring, or oil leaks from rear main seal.
11. 11

    Inspect and prepare crankshaft flange
    Clean crankshaft flange thoroughly with brake cleaner or degreaser, removing all oil, debris, and old thread-locking compound. Inspect rear main seal for leaks; if seepage is present, now is optimal time for seal replacement. Inspect flywheel mounting surface for scoring, cracks, or damage. Verify dowel pins are present and undamaged. Clean flywheel bolt holes in crankshaft flange and verify threads are clean and undamaged.
12. 12

    Install new flywheel
    Align new flywheel with dowel pins on crankshaft flange, ensuring proper orientation (note offset bolt pattern or marking if present). Seat flywheel fully onto flange and dowel pins. Install new flywheel bolts (or cleaned original bolts if verified reusable) with medium-strength thread-locking compound applied to threads. Hand-thread all 8 bolts to prevent cross-threading. Install flywheel holding tool to prevent rotation. Torque flywheel bolts in star pattern to the Aston Martin service-manual specification. These bolts are torque-to-yield (torque-plus-angle) — apply the initial torque then the specified rotation angle per the workshop manual, and always use new bolts. Note: Torque flywheel bolts in star pattern to the service-manual specification. These bolts are typically torque-to-yield (torque plus angle); do not use a single fixed value without verification. Obtain the exact initial torque and subsequent angle specification from the Aston Martin service manual before tightening. Note: Torque flywheel bolts in the manufacturer-specified sequence and to the exact values in the Aston Martin service manual (torque-plus-angle if TTY). Do not use estimated values — the DB9 V12 flywheel bolt spec and TTY status must be confirmed before tightening.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
13. 13

    Install clutch disc and pressure plate
    Insert clutch alignment tool through new clutch disc and into pilot bearing in crankshaft to center disc. Position clutch disc on flywheel with correct orientation (marked side typically faces pressure plate, 'Flywheel Side' marking faces the flywheel (note: a 'Getriebe Seite' / 'transmission side' marking faces the gearbox, the opposite direction)). Position new pressure plate over clutch disc, aligning with dowel pins or previous alignment marks. Install the 6 pressure plate bolts hand-tight. Gradually torque pressure plate bolts in star pattern to the manufacturer specification per the Aston Martin service manual (value to be verified). Remove clutch alignment tool once all bolts are torqued. Note: Gradually torque pressure plate bolts in star pattern to the Aston Martin service-manual specification (verify exact value before tightening). Note: Gradually torque pressure plate bolts in star pattern to the exact manufacturer specification from the Aston Martin service manual (value not yet verified for this platform).
    ⚠Clutch disc must be installed with correct orientation or clutch will not release properly. Verify 'Flywheel Side' marking faces flywheel before tightening pressure plate.
14. 14

    Prepare transmission for installation
    Inspect transmission input shaft splines for damage or wear. Apply small amount of high-temperature clutch grease to input shaft splines (do not over-grease as excess can contaminate clutch). Install new release bearing on input shaft housing if not already installed. Verify pilot bearing in crankshaft is in good condition. Clean transmission bellhousing mating surface and engine block mating surface thoroughly.
15. 15

    Install transmission assembly
    Position transmission on transmission jack and raise to alignment height with engine. Ensure transmission is level and aligned with engine block dowel pins. Carefully slide transmission forward, guiding input shaft through clutch disc center and into pilot bearing. Input shaft must pass through clutch alignment tool location without resistance. Continue sliding transmission forward until bellhousing contacts engine block and dowel pins engage. If resistance is encountered, do not force; lower slightly and re-align. Install all bellhousing-to-engine bolts hand-tight, then torque in star pattern to the manufacturer specification per the Aston Martin service manual (value to be verified). Note: Install and torque all bolts to the Aston Martin service-manual specification, following the correct sequence (verify exact values before tightening). Note: Install all bellhousing/torque-tube bolts hand-tight, then torque in the specified sequence to the exact manufacturer specification from the Aston Martin service manual (value not yet verified for this platform).
16. 16

    Install starter motor and crossmember
    Install starter motor into bellhousing, ensuring proper gear engagement with flywheel ring gear. Install starter mounting bolts and torque to specification. Reconnect starter electrical connections including main battery cable and solenoid wire. Raise transmission crossmember into position and install chassis mounting bolts on both sides. Install transmission mount-to-crossmember bolts and torque all fasteners to specification. Remove transmission jack once crossmember is secure and transmission weight is fully supported.
17. 17

    Reconnect clutch hydraulic system and shift linkage
    Reconnect clutch slave cylinder hydraulic line or reinstall external slave cylinder with new mounting bolts if applicable. Bleed clutch hydraulic system to remove air. Reconnect shift linkage to transmission selector lever using connecting pin or bolt, ensuring proper alignment and engagement. Reconnect all electrical connectors to transmission including reverse light switch and speed sensors, verifying secure connection of each.
18. 18

    Install propshaft
    Raise propshaft into position, supporting center bearing. Align propshaft flanges with previously made alignment marks on transmission and differential flanges. Install center bearing mounting bolts to chassis and torque to specification. Install the 6 bolts securing propshaft to transmission flange, aligning marks and torquing to specification. Install the 6 bolts securing propshaft to differential flange and torque to specification. Verify propshaft rotates freely without binding.
19. 19

    Install exhaust system and refill fluids
    Raise exhaust mid-section into position, aligning flanges with header outlets. Install new exhaust gaskets if original gaskets were damaged. Install flange bolts and torque to the service-manual specification (value to be verified). Connect exhaust hangers at rear mounting points. Refill the rear transaxle with the correct fluid and quantity for the verified transmission variant per the Aston Martin service manual: the Graziano 6-speed manual transaxle uses manual gearbox oil (small quantity) and is NOT filled with ATF; the ZF 6HP26 Touchtronic automatic uses ZF Lifeguard 6 ATF. Do not fill a manual transaxle with ATF or an automatic with gear oil. Install the drain plug with a new crush washer and torque to the service-manual specification. Note: Install transmission drain plug with new sealing washer and torque to the service-manual specification (value to be verified). Note: Remove drain pan and refill transaxle with the correct fluid per service manual. If ZF 6HP26 automatic: use ZF Lifeguard 6 ATF and set level via the fill-plug/overflow procedure at the specified fluid temperature (sealed unit, no dipstick). Drain-and-fill capacity is approximately 4-5 quarts; total dry-fill capacity is higher — verify exact capacity against the Aston Martin service manual before filling. If manual transaxle: refill with specified manual gearbox oil to the correct level. Verify exact capacity per service manual. Note: Remove drain pan and refill the manual transaxle with the OEM-specified gear oil (NOT ATF) to the correct capacity per the service manual (verify exact type and fill volume). Install drain plug with a new crush washer and torque to the manufacturer-specified value. Note: Install the transaxle drain plug with a new crush washer and torque to the manufacturer-specified value from the Aston Martin service manual (verify exact drain plug torque). Note: Install flange bolts and torque to the manufacturer-specified value from the Aston Martin service manual (verify exact exhaust flange torque).
    Torque spec

    Transmission Drain Plug33 Nm (24 lb-ft)
20. 20

    Final installation and system check
    Install engine undertray panels with Torx fasteners. Reconnect negative battery terminal. Lower vehicle from lift. Start engine and verify no abnormal noises from flywheel or clutch area. With engine running, depress clutch pedal and verify smooth engagement and disengagement. Test shift through all gears with engine running and clutch depressed to verify proper clutch function. Road test vehicle to verify clutch engagement point, smooth shifting, and absence of vibration or noise from drivetrain.

Reassembly

1. Reassembly follows removal steps in reverse order with attention to torque specifications and alignment marks.
2. Always use new flywheel bolts if torque-to-yield specification is confirmed in service manual.
3. Clutch disc orientation is critical; verify 'Flywheel Side' marking faces flywheel before final installation.
4. Transmission input shaft must align smoothly through clutch disc; forcing installation will damage clutch disc or pressure plate.
5. Bleed clutch hydraulic system after reconnection to ensure proper clutch operation.

Verification

• Start engine and listen for abnormal noises from flywheel area; properly installed flywheel should produce no vibration or rattling.
• Verify clutch pedal has proper resistance and engagement point is in normal range (typically mid-pedal travel).
• Test shift into each gear with engine running and clutch depressed; all gears should engage smoothly without grinding.
• Road test vehicle at various speeds; verify smooth acceleration, no clutch slippage under load, and no driveline vibration.
• Verify no fluid leaks from transmission drain plug, clutch hydraulic connections, or rear main seal area after test drive.

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