Front Struts - Pair

This procedure replaces both front strut assemblies on the 2009 Aston Martin DB9, requiring suspension disassembly, strut removal from both tower and lower mounting points, and precise torque specifications.

Warnings

Tools required

Parts

• Front strut assembly (left) × 1 — Use OEM specification or Bilstein/Koni equivalent
• Front strut assembly (right) × 1 — Use OEM specification or Bilstein/Koni equivalent
• Strut tower mounting nuts (if corroded) × 6 — M10 or M12 hex flange nuts
• Sway bar link nuts (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground (do not remove).
3. Lift front of vehicle using floor jack at designated front lift point (consult owner's manual for exact location on subframe).
4. Place jack stands under front subframe or pinch weld reinforced lift points on both sides. Lower vehicle onto stands and verify stability.
5. Remove both front wheels completely and set aside.
6. Spray penetrating oil on all suspension fasteners to be removed (strut tower nuts, lower strut bolts, sway bar link nuts) and allow to soak for 10-15 minutes.

Procedure

1. 1

   Access front strut tower mounting points
   Open the hood and locate the strut tower mounting points in the engine bay. On each side, the strut tower will have mounting nuts securing the top of the strut assembly (VERIFY exact count against Aston Martin service documentation; commonly 3 studs/nuts). These are typically located near the fender well, visible from above. Clear any engine covers or hoses that may obstruct access to the strut tower nuts. On the DB9, check for any plastic cap, cover, or trim over the tower nuts and remove it if present (method varies—may pull upward or use retaining clips). Note: On each side, the upper damper mount secures to the body with a number of fasteners that must be confirmed against DB9 service documentation (commonly 3, but verify). Note: On each side, verify the exact number of upper damper mounting nuts against Aston Martin service documentation, as the DB9 uses a double-wishbone coilover damper rather than a MacPherson strut.
2. 2

   Remove strut tower mounting nuts (first side)
   Working on the driver's side first, use a socket wrench to remove the upper mounting nuts securing the top of the strut to the strut tower (VERIFY exact count against Aston Martin service documentation). Ensure the strut assembly is supported before removing the upper fasteners. Hold the strut shaft with an Allen key if it begins to spin (the center nut typically goes through the strut shaft). Do NOT allow the strut to drop once the nuts are removed—the lower mounting is still attached. Support the strut assembly from below if necessary. Note: Strut tower mounting nuts (if corroded)
3. 3

   Disconnect sway bar link (first side)
   Locate the front anti-roll bar drop link connecting the sway bar to the lower control arm/damper. The link will have a nut on the attachment point; verify the exact mounting location against DB9 service documentation. Hold the sway bar link shaft with an appropriately sized Allen key inserted into the center of the stud to prevent spinning (verify size against DB9 documentation), then remove the nut with a socket wrench. Once removed, pull the link stud out of the mounting bracket on the strut. Note: Hold the sway bar link shaft with an appropriately sized Allen key inserted into the center of the stud to prevent spinning (verify hex size on your specific link), then remove the upper nut with a socket wrench. Note: Hold the sway bar link shaft with the appropriate Allen key or wrench (verify size against service documentation) inserted into the center of the stud to prevent spinning, then remove the upper nut with a socket wrench.
   Torque spec

   Sway Bar Link48 Nm (35 lb-ft)
4. 4

   Disconnect ABS/wheel speed sensor (first side)
   Locate the ABS wheel speed sensor wire attached to the strut body or steering knuckle assembly. There will be one or more mounting brackets or clips holding the wire to the strut. Carefully remove these clips (typically push-tabs or small Torx fasteners) and route the wire clear of the strut assembly. Trace the wire back to its connector point and disconnect if necessary to prevent damage during strut removal.
5. 5

   Remove lower strut mounting bolts (first side)
   The lower portion of the damper is secured to the lower control arm (or lower spring seat) via a through-bolt and nut. Verify the exact lower damper attachment against DB9 service documentation before removal. Locate the lower damper through-bolt (verify exact count and location against Aston Martin DB9 service documentation). Use a breaker bar and socket to remove the bolt(s) completely. Note the orientation and any shims or alignment marks. Once the lower through-bolt is removed, the lower end of the damper will be free from the lower control arm bracket—maneuver it clear without prying on any chassis component. Note: The lower portion of the damper is secured to the lower control arm (not the steering knuckle) via a mounting bolt/clevis. VERIFY the exact lower attachment method and fastener count against Aston Martin service documentation before proceeding, as the DB9 uses a double-wishbone (coil-over) layout rather than a MacPherson strut with a knuckle pinch-fork. Note: The lower portion of the damper on the DB9 is attached to the lower control arm (not a pinch-fork knuckle) via a through-bolt. Verify the exact lower damper mounting configuration against Aston Martin service documentation before proceeding, as the DB9 uses a double-wishbone suspension rather than a MacPherson strut.
   Torque spec

   Strut Bolts156 Nm (115 lb-ft)
6. 6

   Remove strut assembly (first side)
   With the top nuts and lower bolts removed, carefully maneuver the strut assembly out from the wheel well. Tilt the bottom of the strut outward first, then lower it down and out from the strut tower. The strut is heavy (approximately 20-30 lbs with spring)—use both hands and control its descent. Set the old strut aside on a clean work surface.
7. 7

   Inspect mounting points and hardware
   Inspect the strut tower mounting surface for cracks, rust, or deformation. Inspect the lower control arm damper mounting bracket/eye area for cracks or damage. Clean all mounting surfaces and threads with a wire brush. Inspect all fasteners for thread damage—replace any strut tower nuts or lower strut bolts that show corrosion, stretched threads, or damage. Check the condition of the sway bar link—if the rubber boot is torn or the joint has excessive play, replace the link now.
8. 8

   Install new strut assembly (first side)
   Position the new strut assembly into the wheel well from below, threading the top mounting studs through the strut tower holes first. You may need an assistant or a floor jack under the lower control arm to support the strut while aligning it. Once the top studs are through the tower, align the lower damper eye/mount with the lower control arm bracket and insert the lower through-bolt. Verify the exact lower damper attachment against DB9 service documentation. Ensure the lower damper eye/mount is fully aligned with the lower control arm bracket and the through-bolt passes freely before proceeding.
9. 9

   Install lower strut bolts (first side)
   Insert the lower damper through-bolt(s) through the lower control arm bracket and damper eye (verify exact count against Aston Martin DB9 service documentation). Ensure any alignment marks or shims removed during disassembly are reinstalled in their original positions. Thread the nut(s) onto the bolt(s) and hand-tighten only. Do NOT apply final torque yet—the rubber-bushed lower damper mount MUST be final-torqued with the vehicle weight on the suspension at normal ride height.nsures even clamping force on the strut housing.
   Torque spec

   Strut Bolts156 Nm (115 lb-ft)
10. 10

    Install strut tower nuts (first side)
    From the engine bay, install the upper damper mounting nuts onto the studs protruding through the tower (verify exact count against Aston Martin DB9 service documentation; commonly 3). Hand-tighten all three nuts first. If the center stud begins to spin, hold it with an Allen key inserted into the top of the strut shaft. Using a torque wrench, torque all upper mount nuts to specification in a star/alternating pattern (if applicable) to ensure even loading. Reinstall any plastic cap or cover over the tower nuts.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)
11. 11

    Reconnect sway bar link (first side)
    Insert the upper stud of the sway bar link into the mounting bracket on the strut assembly. Thread the nut onto the stud and hand-tighten. Hold the sway bar link shaft with the appropriate Allen key or wrench (verify size against service documentation) to prevent spinning, then torque the nut to specification using a torque wrench.
    Torque spec

    Sway Bar Link48 Nm (35 lb-ft)
12. 12

    Reconnect ABS sensor wire (first side)
    Route the ABS wheel speed sensor wire back along the strut body, reinstalling all mounting clips and brackets removed during disassembly. Ensure the wire has adequate slack and will not be pinched or stretched during suspension travel. Reconnect any electrical connectors that were disconnected.
13. 13

    Repeat for passenger side
    Repeat steps 2 through 12 for the passenger side strut assembly. Follow the exact same sequence: remove strut tower nuts, disconnect sway bar link, disconnect ABS sensor, remove lower strut bolts, remove old strut, inspect components, install new strut, install lower bolts, install tower nuts, reconnect sway bar link, and reconnect ABS sensor.
14. 14

    Reinstall wheels and lower vehicle
    Reinstall both front wheels, threading the lug nuts on by hand first. Tighten the lug nuts in a star pattern with a socket wrench, but do NOT torque to final specification yet. Raise the vehicle slightly with the floor jack to unload the jack stands, then remove the jack stands. Lower the vehicle completely to the ground so that the suspension is at normal ride height with vehicle weight on the wheels.
15. 15

    Final torque wheel lug nuts
    With the vehicle on the ground and full weight on the suspension, use a torque wrench to torque all wheel lug nuts to specification in a star pattern. This ensures even pressure on the wheel hub and prevents warping.
    Torque spec

    Wheel Lug Nuts89 Nm (66 lb-ft)

Reassembly

1. Reassembly is covered in the installation steps above (steps 8-15).
2. Ensure all fasteners are torqued to specification and in the correct sequence.
3. Verify that all ABS sensor wires are properly routed and secured with all original clips.
4. Double-check that sway bar links are properly connected on both sides.

Verification

• Before driving, bounce each front corner of the vehicle several times and verify the struts dampen the motion without excessive bouncing or noise.
• Start the vehicle and verify no ABS warning lights appear on the instrument cluster.
• Perform a slow-speed test drive in a safe area, checking for unusual noises, vibrations, or handling issues.
• Inspect all fasteners for proper tightness after test drive.
• Schedule a four-wheel alignment at a qualified shop immediately—this is MANDATORY after strut replacement.
• After alignment and first 50-100 miles of driving, re-check torque on all wheel lug nuts and verify no suspension noises have developed.

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