Pressure Plate

Complete removal and replacement of the pressure plate assembly, requiring full transmission removal and rear subframe lowering on the 2009 Aston Martin DB9 6.0L V12.

Warnings

Tools required

Parts

• Pressure plate assembly (6.0L V12) × 1 — Use OEM specification
• Clutch disc (6.0L V12) × 1 — Use OEM specification
• Release bearing (throw-out bearing) × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification
• Flywheel bolts (if TTY type) × 8 — Use OEM specification
• Driveshaft coupling bolts (new) × 6 — Use OEM specification
• Rear subframe mounting bolts (new recommended) × 4 — Use OEM specification

Fluids

• Touchtronic 6-speed ZF ATF — 9.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Disconnect negative battery terminal and isolate the cable to prevent electrical shorts during disassembly.
3. Raise vehicle on two-post lift to full working height and support on axle stands at reinforced jacking points.
4. Remove rear wheels to access suspension and brake components.
5. Allow exhaust system to cool completely if vehicle was recently driven.
6. Have drain pans, catch containers, and fluid transfer equipment ready.
7. Photograph or mark driveshaft-to-differential flange orientation for correct reinstallation phasing.

Procedure

1. 1

   Remove exhaust system rear section
   Disconnect exhaust hangers at the rear mufflers and mid-section. Remove exhaust clamps or flange bolts connecting the rear exhaust section to the mid-pipes. The DB9 uses a multi-piece exhaust; expect Torx or E-Torx fasteners at flanges. Lower the rear exhaust section and set aside. Full exhaust removal may not be necessary, but clearance around the rear-mounted transaxle bell housing is required for lowering the rear subframe and separating the clutch assembly.
2. 2

   Drain transmission fluid
   Position a large drain pan under the transmission. Locate the transmission drain plug on the bottom of the transmission case and remove it using the appropriate socket. Allow fluid to drain completely (verify exact capacity against OEM service information for this transaxle). Install a new crush washer on the drain plug and reinstall the plug, torquing to specification. Leave the drain plug installed but note that additional fluid will drain when the transmission is separated. Note: Allow fluid to drain completely (capacity per OEM specification — verify before refill, typically in the 2.5-4 quart range for the transaxle, not the 9.5 quart figure). Note: Allow fluid to drain completely (verify OEM fluid capacity before refilling).
   Torque spec

   Transmission Drain Plug35 Nm (26 lb-ft)
3. 3

   Disconnect driveshaft
   Mark the driveshaft flange orientation relative to the differential flange using a paint pen or marker to maintain balance during reinstallation. Remove the bolts securing the propshaft/torque tube coupling at the appropriate flange (verify exact bolt count and coupling location against OEM documentation). Support the driveshaft and carefully lower it, then secure it out of the way with wire or a strap to prevent damage. Do not allow the driveshaft to hang unsupported.
4. 4

   Disconnect transmission wiring and hydraulics
   Locate and disconnect all electrical connectors on the transmission, including the reverse light switch, speed sensors, and shift solenoid connectors. Release any wiring harness clips or brackets securing the harness to the transmission body. If equipped with a manual clutch, locate and disconnect the clutch hydraulic line at the slave cylinder; verify the clutch actuation type (manual hydraulic vs. automated transaxle) against OEM documentation before proceeding, as the Touchtronic automatic does not use a conventional slave cylinder. Have a container ready to catch hydraulic fluid. Cap or plug the hydraulic line to prevent contamination and fluid loss. Note: Disconnect the hydraulic clutch line at the clutch slave/concentric cylinder located at the rear transaxle. Have a container ready to catch hydraulic fluid. Note: Locate and disconnect all electrical connectors on the transaxle (verify actual connectors — the Touchtronic 2 uses an electrohydraulic actuation unit rather than conventional shift solenoids/reverse switch). Release any wiring harness clips or brackets. Disconnect the hydraulic clutch actuation line at the actuator/slave unit, verifying its location per OEM documentation.
5. 5

   Remove transmission crossmember and mount
   Support the transaxle with a transmission jack positioned securely under the transaxle case body. Remove the fasteners securing the transmission mount to the crossmember and chassis. The DB9 uses a rear-mounted transmission; expect multiple Torx or E-Torx bolts securing the crossmember to the chassis rails. Remove the crossmember completely and set aside. Keep the transmission jack in place supporting the weight.
6. 6

   Disconnect gear selector linkage
   Locate the gear selector mechanism connected to the transmission. On the DB9, the gear selector arrangement depends on whether the car is a conventional manual or Touchtronic automated-manual; identify the fitted configuration and disconnect the selector shaft/linkage or actuator accordingly. Remove the fasteners (typically Torx bolts or clips) securing the linkage to the transmission selector shaft. Mark the orientation if adjustment is required during reinstallation. Disconnect and secure the linkage away from the transmission. Note: On the DB9 Touchtronic transaxle, gear selection is electronic (shift-by-wire); verify whether any mechanical linkage or park-lock cable is present and disconnect only what OEM documentation specifies. Note: Depending on gearbox type (manual vs. Touchtronic automated-manual), disconnect the appropriate shift mechanism. Verify whether this car uses mechanical selector cables/linkage (manual) or electrohydraulic actuation (Touchtronic) before disconnecting.
7. 7

   Support engine and remove bell housing access
   Install an engine support bar across the engine bay or use overhead support chains attached to the engine lifting points. The engine must be supported independently as the transmission will be removed. Remove any heat shields or covers around the transmission bell housing area. There may be dust covers or inspection plates secured with Torx fasteners—remove these to access the pressure plate.
8. 8

   Prepare rear subframe for lowering
   The DB9 requires lowering the rear subframe to create clearance for transmission removal. Disconnect the rear anti-roll bar (sway bar) links from the subframe or lower control arms using appropriate sockets. Disconnect the rear shock absorbers from their lower mounts (typically large Torx or E-Torx bolts). Support the rear differential and subframe assembly with a second transmission jack or adjustable support stand. Mark the position of the subframe relative to the chassis using a paint pen for realignment during installation.
9. 9

   Lower rear subframe
   Locate the four main subframe mounting bolts securing the rear subframe to the chassis (two forward, two rearward). These are large-diameter bolts accessed from underneath. Loosen all four bolts gradually, then remove them completely. Carefully lower the subframe the minimum distance required for clearance, per OEM service procedure, while supporting all suspension and driveline components. This provides clearance to angle the transmission down and rearward during removal. Do not lower excessively or suspension/differential components may become stressed or damaged.
10. 10

    Remove transmission-to-engine bolts
    Locate all bell housing bolts securing the transmission to the engine block. The DB9 uses a rear transaxle joined to the engine via a torque tube; refer to OEM service information for the exact fasteners and sequence for separating the transaxle and torque tube — do not assume a conventional engine-block bell housing bolt pattern. Use Torx or E-Torx sockets as appropriate. Remove the transaxle/torque-tube joining bolts per OEM sequence (verify exact count and positions against OEM documentation), leaving the most accessible upper fasteners for last. Ensure the transmission jack is securely supporting the transaxle weight. Remove the final bolts while steadying the transaxle. Note: The DB9 engine-to-bellhousing joint uses multiple bolts of varying lengths positioned around the perimeter (verify exact count and positions against OEM service information). Note: Locate all bolts securing the transaxle bell housing to the torque tube (verify exact bolt count, positions, and lengths against OEM documentation).
11. 11

    Separate and remove transmission
    With all bell housing bolts removed, carefully slide the transmission rearward away from the engine. The input shaft will disengage from the clutch disc and pressure plate. Move slowly and keep the transmission level to avoid binding the input shaft. Once clear of the clutch assembly, lower the transmission on the jack and roll it out from under the vehicle. Have an assistant help guide the transmission as it is heavy and awkward.
12. 12

    Inspect clutch assembly and flywheel
    With the transmission removed, the pressure plate, clutch disc, and flywheel are now visible. Inspect the clutch disc for wear, oil contamination, glazing, or cracks. Check the pressure plate friction surface for hot spots, cracks, or warping. Inspect the flywheel surface for scoring, heat discoloration, or damage. If the flywheel shows significant wear, it should be resurfaced or replaced. Check the release bearing (throw-out bearing) on the transmission input shaft housing for roughness or noise—replace if worn.
13. 13

    Lock flywheel and remove pressure plate
    Install a flywheel holding tool to prevent the flywheel from rotating. The pressure plate is secured to the flywheel with several bolts arranged in a circular pattern (verify exact count against OEM service information). Using a Torx or E-Torx socket, loosen each bolt gradually in a cross (star) pattern, turning each bolt 1-2 turns at a time to release spring pressure evenly. Once all bolts are loose, remove them completely. Carefully remove the pressure plate assembly and clutch disc, supporting both as they are released. Keep the clutch disc clean and avoid touching the friction surfaces. Note: The pressure plate is secured to the flywheel with its mounting bolts arranged in a circular pattern (verify exact count against OEM specification before ordering fasteners). Note: The pressure plate is secured to the flywheel with bolts arranged in a circular pattern (verify exact bolt count against OEM documentation).
14. 14

    Clean and prepare flywheel surface
    With the pressure plate and clutch disc removed, clean the flywheel surface thoroughly using a wire brush and parts cleaning solvent. Remove all debris, clutch dust, and oil residue. Inspect the flywheel mounting bolts securing the flywheel to the crankshaft for wear or stretching (verify exact bolt count against OEM service information). If replacing the flywheel or if bolts are TTY type, remove the flywheel (bolt count and TTY status per OEM specification), clean the crankshaft flange, and reinstall with new bolts torqued in the OEM-specified pattern to specification. If the flywheel surface is acceptable, leave it installed and proceed. Note: Inspect the flywheel mounting bolts (count per OEM specification) securing the flywheel to the crankshaft for wear or stretching. Note: Inspect the flywheel mounting bolts (verify exact bolt count securing flywheel to crankshaft against OEM documentation) for wear or stretching.
15. 15

    Install new clutch disc and pressure plate
    Place the new clutch disc onto the flywheel with the correct orientation—the side marked 'flywheel side' or 'gearbox/transmission side' must face the correct direction (typically the protruding hub faces the transmission). Insert the clutch alignment tool through the clutch disc and into the pilot bearing in the center of the flywheel to center the disc. Position the new pressure plate over the clutch disc and align the bolt holes with the flywheel. Install all pressure plate bolts (count per OEM specification) and hand-tighten. Tighten the bolts gradually in a star pattern to the exact OEM-specified torque (verify the precise value against Aston Martin factory service information before tightening — do not rely on a generic range). Remove the alignment tool only after the pressure plate is fully torqued. Note: Tighten the bolts gradually in a star pattern to the OEM-specified torque (do not rely on a generic range — confirm the exact value in Aston Martin service data). Note: Tighten the bolts gradually in a star pattern to the OEM-specified torque (verify exact value with OEM specification before tightening).
    ⚠Do not touch the clutch disc friction surfaces with bare hands as oil contamination will cause slippage and premature failure.
16. 16

    Install release bearing and prepare transmission
    Install the new release bearing (throw-out bearing) onto the transmission input shaft bearing retainer or fork, depending on design. Ensure the bearing clips or retainers are fully seated. Lubricate the input shaft splines lightly with high-temperature clutch grease (do not over-apply as excess grease can contaminate the clutch). Inspect the transmission input shaft for damage or burrs. Verify the clutch alignment tool can still pass through the clutch disc and into the pilot bearing—if not, realign before proceeding.
17. 17

    Reinstall transmission
    Position the transmission on the transmission jack and raise it into position behind the engine. Align the transmission input shaft with the clutch disc splines (the alignment tool ensures correct positioning). Carefully slide the transmission forward, guiding the input shaft into the clutch disc. The transmission should slide smoothly onto the engine once the splines engage. Do not force it—if resistance is felt, lower slightly and realign. Once the bell housing is flush with the engine block, install all bell housing bolts and tighten them evenly in a cross pattern. Torque to the exact OEM specification (verify value against factory service information). Note: Torque the transaxle/torque-tube fasteners to the exact OEM specification (confirm values in Aston Martin service data; do not use a generic range). Note: Once the transaxle bell housing mates with the torque tube, install all bolts and tighten evenly in a cross pattern. Torque to OEM specification (verify exact value with OEM documentation).
18. 18

    Raise and secure rear subframe
    Raise the rear subframe back into its original position using the supporting jack, aligning it with the marks made during disassembly. Install the main subframe mounting bolts (count and type per OEM) and tighten them evenly to the exact OEM torque/angle specification (these may be torque-to-yield and require replacement — confirm in Aston Martin service data). Reconnect the rear shock absorbers to their lower mounts and torque fasteners to specification. Reconnect the anti-roll bar links and torque to specification. Note: Install the subframe mounting bolts and torque to the exact OEM specification and tightening sequence (verify values, count, and any torque-angle requirement against factory service information). Note: Install the four main subframe mounting bolts (new, as these are likely one-time-use) and tighten evenly. Torque to OEM specification (verify exact value and whether a torque-angle procedure applies).
19. 19

    Reconnect transmission components
    Reinstall the transmission crossmember and mount, torquing all fasteners to specification. Reconnect the gear selector linkage to the transmission selector shaft, ensuring correct orientation and adjustment. Reconnect all electrical connectors to the transmission (speed sensors, solenoids, reverse light switch). Reconnect the hydraulic clutch line to the slave cylinder and bleed the clutch hydraulic system if necessary. Secure all wiring harness clips and brackets.
20. 20

    Reconnect driveshaft and refill transmission
    Raise the driveshaft into position and align the marks made during disassembly to maintain balance. Install the new driveshaft coupling bolts and torque to the exact OEM specification (verify value and bolt count against factory service information). Refill the transaxle with the OEM-specified ZF ATF through the correct fill/level plug to the specified level (verify exact fluid type and capacity against OEM service information). Reinstall the drain plug with a new crush washer and torque to specification. Verify fluid level per OEM procedure (may require running engine and checking at operating temperature). Note: Remove the transaxle drain/fill plug and refill with the exact OEM-specified lubricant and quantity for the fitted transaxle (verify fluid type — gear oil vs. ATF — and capacity in Aston Martin service data; the 9.5 quart figure is not correct for this transaxle). Note: Install the new driveshaft coupling bolts (count per OEM) and torque to the exact OEM specification (confirm values in Aston Martin service data). Note: Install the new propshaft/torque-tube coupling bolts and torque to OEM specification (verify exact bolt count and torque value with OEM documentation). Note: Remove the transaxle fill/drain plug and refill with the OEM-specified fluid (verify correct fluid type — ATF for Touchtronic or gear oil for manual — and exact capacity against OEM documentation).
    Torque spec

    Transmission Drain Plug35 Nm (26 lb-ft)
21. 21

    Reinstall exhaust and final reassembly
    Reinstall the rear exhaust section, securing all hangers and flange bolts. Torque exhaust fasteners to specification. Reinstall any heat shields or covers removed during disassembly. Reinstall rear wheels and torque lug nuts to specification in a star pattern. Remove engine support equipment. Reconnect the negative battery terminal.
22. 22

    Test and adjust clutch operation
    Lower the vehicle from the lift. Start the engine and verify normal operation with no unusual noises from the transmission or clutch area. Test clutch engagement and disengagement by depressing the clutch pedal and shifting through all gears with the engine running. The clutch should engage smoothly without slipping or chattering. Verify proper clutch pedal feel and travel. If the clutch hydraulic system was opened, bleed the system until pedal feel is firm. Perform a test drive to verify clutch operation under load, checking for smooth engagement, no slipping, and proper gear selection. Re-check transmission fluid level after test drive.

Reassembly

1. Reassembly follows the reverse order of disassembly with the following critical notes: ensure the clutch disc is oriented correctly with the hub protruding toward the transmission before installing the pressure plate; use the clutch alignment tool throughout pressure plate installation; torque all fasteners to specification in the correct sequence (flywheel bolts and pressure plate bolts in star pattern); replace all crush washers, TTY bolts, and one-time-use fasteners; realign the driveshaft marks to maintain balance; refill transmission fluid to the correct level; bleed the clutch hydraulic system if the line was disconnected; verify all electrical connectors are fully seated and secured.

Verification

• Start the engine with the clutch pedal depressed and verify the transmission can be shifted into gear smoothly without grinding or resistance.
• Verify the clutch pedal feel is firm and consistent with proper hydraulic pressure (no sponginess).
• Perform a test drive and verify smooth clutch engagement without slipping, particularly under moderate acceleration.
• Check for any unusual noises from the transmission, clutch, or driveshaft during operation.
• Verify no fluid leaks from the transmission drain plug, hydraulic clutch line, or bell housing area.
• Confirm the transmission shifts smoothly through all gears under various driving conditions.
• Re-check transmission fluid level after the vehicle reaches operating temperature and top off if necessary.

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