Strut Assembly - Front

Complete removal and replacement of the front strut assemblies on a 2009 Aston Martin DB9, including disassembly of wheel/brake components and upper strut tower mounting.

Warnings

Tools required

Parts

• Front strut assembly (left) × 1 — Use OEM Aston Martin specification or equivalent OE replacement
• Front strut assembly (right) × 1 — Use OEM Aston Martin specification or equivalent OE replacement
• Strut top mount hardware kit × 1 — OEM self-locking nuts recommended
• Lower ball joint pinch bolt (if reuse not recommended) × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
3. Lift front of vehicle using manufacturer jacking points and support securely on jack stands
4. Remove both front wheels completely
5. Spray all suspension fasteners with penetrating oil and allow 10-15 minutes to soak

Procedure

1. 1

   Access upper strut mounting points
   Open the hood and locate the upper strut tower mounting area. The DB9 upper strut mount is secured by several fasteners accessible from the engine bay — verify the exact count against factory documentation before removal. Remove any plastic covers or trim pieces covering the strut tower mounting area using the appropriate tools (verify fastener head type before removal). Note the orientation of any washers or spacers on the upper mount studs. Note: The DB9 upper strut mount is secured by a number of fasteners accessible from the engine bay (verify exact count against the factory service manual). Note: The DB9 upper strut/damper mount is secured by fasteners accessible from the engine bay (verify exact count against factory documentation).
2. 2

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector near the strut assembly on the inner fender area. Press the locking tab and disconnect the electrical connector. Carefully remove any routing clips securing the sensor wire to the strut or control arm, noting the exact routing for reinstallation. Use a pick tool if necessary but avoid damaging the wire insulation.
3. 3

   Remove brake caliper
   Remove the brake caliper mounting bolts (verify exact count and access location against the factory service manual; verify the caliper mounting method against the factory service manual before removal). Support the caliper with a wire hanger or zip ties to the suspension or frame to avoid strain on the brake line. DO NOT allow the caliper to hang by the brake hose. Leave the brake line connected to the caliper.
4. 4

   Disconnect outer tie rod end
   Remove the nut securing the outer tie rod end to the steering knuckle (self-locking nut or castle nut with cotter pin depending on configuration — verify before removal). If a cotter pin is present, remove it first. Use a ball joint separator or pickle fork to separate the tie rod end taper from the knuckle. Apply penetrating oil and strike the knuckle boss area (not the ball joint stud) to aid separation. Count the number of visible threads on the tie rod before removal to aid in approximate alignment during reassembly. Note: Remove the nut securing the outer tie rod end to the steering knuckle (verify whether it is a self-locking nut or a castle nut with cotter pin per the factory service manual). If a cotter pin is present, remove it first.
5. 5

   Separate lower ball joint from knuckle
   Locate the lower ball joint connection between the lower control arm and the steering knuckle. Verify the exact fastening method against factory documentation — the DB9 lower ball joint attachment method (castle nut on a tapered stud vs. pinch bolt) must be verified against factory documentation. Remove the securing fastener, then separate the ball joint taper from the knuckle using an appropriate separator. The knuckle and strut assembly should now pivot freely. Note: Locate the lower ball joint retaining fastener connecting the lower control arm ball joint to the steering knuckle. Verify the exact retention method (castle nut on a tapered stud vs. pinch bolt) against the factory service manual before proceeding. Separate the ball joint from the knuckle taper using the appropriate method. The knuckle and strut assembly should now pivot freely. Note: Locate the lower ball joint attachment to the steering knuckle. Depending on configuration this may be a castle nut on a tapered stud or a pinch-bolt clamp. Remove the retaining fastener (verify type against factory documentation) and separate the ball joint from the knuckle using the appropriate method. Verify the exact attachment design for the 2009 Aston Martin DB9 before proceeding.
6. 6

   Remove lower strut mounting fasteners
   Identify the lower strut-to-knuckle mounting fasteners. Verify the lower strut mounting method and fastener count against the factory service manual before removal (the DB9 may use a different number of bolts or a different mounting point than assumed here). Support the knuckle/strut assembly with one hand or a floor jack positioned under the lower control arm. Remove both bolts completely. The knuckle assembly will now be free but still attached to the hub/rotor. Note: Identify the lower strut mounting fasteners. Verify the exact count and configuration against factory documentation before removal, as the DB9's double-wishbone arrangement may differ from a conventional two-bolt knuckle bracket. Note: The DB9 damper lower mount attaches to the knuckle or lower control arm bracket (verify exact attachment point and bolt count against factory documentation).
7. 7

   Remove upper strut mount fasteners
   From the engine bay, support the strut assembly from below with a floor jack or have an assistant support the weight. Remove the upper strut mount fasteners securing the strut tower mount to the chassis (verify exact count against the factory service manual). These are typically self-locking nuts. Once all fasteners are removed, carefully lower the strut assembly down and out of the wheel well. Note: Remove the upper strut mount fasteners securing the mount to the chassis (verify exact count against factory documentation).
8. 8

   Transfer components to new strut (if required)
   If installing a complete strut assembly, this step may be skipped. If transferring components from old to new strut: Install spring compressors on the coil spring, alternating sides and compressing evenly until spring tension is fully relieved from the upper mount. Remove the strut shaft nut while holding the shaft with an appropriately sized wrench on the shaft flats (verify size against the specific component). Remove upper mount, bearing, spring seat, bump stop, and coil spring. Inspect all components for wear. Transfer usable components to new strut in reverse order, ensuring spring compressors maintain control until upper mount is secured. Note: Remove the strut shaft nut while holding the shaft with the appropriate tool (verify shaft retention feature and nut size against factory documentation).
9. 9

   Install new strut assembly to upper mount
   Lift the new/rebuilt strut assembly into position from below, aligning the upper mount studs with the strut tower holes. Thread on the three upper mounting fasteners by hand to hold the assembly in place. Do not fully tighten yet. Ensure the upper mount orientation matches the original installation (mounting tabs aligned with chassis reference points).
10. 10

    Install lower strut mounting fasteners
    Align the strut lower mounting bracket with the steering knuckle bracket. Insert both lower mounting bolts and thread nuts onto the fasteners by hand. Do not fully tighten yet. Ensure proper alignment of all mounting surfaces and that no wiring or brake lines are pinched.
11. 11

    Reconnect lower ball joint to knuckle
    Guide the lower ball joint into the steering knuckle taper. Install the lower ball joint retaining fastener (castle nut on tapered stud or pinch bolt, matching the design verified in disassembly) and tighten to specification (see torque requirements). Verify the ball joint is fully seated in the knuckle taper before final tightening.
12. 12

    Reconnect outer tie rod end
    Insert the tie rod end stud into the steering knuckle taper. Install a new tie rod end retaining nut (self-locking nut or castle nut with new cotter pin as specified by the factory service manual) and tighten to specification. If equipped with a castle nut and cotter pin, align the slots with the stud hole and install a new cotter pin, spreading the ends properly. Ensure the tie rod end is at approximately the same thread position as before removal. Note: Remove the nut securing the outer tie rod end to the steering knuckle (verify whether a castle nut with cotter pin or a self-locking nut is used against factory documentation).
13. 13

    Reinstall brake caliper
    Remove the support wire/zip ties from the brake caliper. Position the caliper over the brake rotor and align the mounting bolt holes. Install the caliper mounting bolts and tighten to specification. Verify the caliper moves freely and brake pads contact the rotor properly.
14. 14

    Torque all suspension fasteners
    With the vehicle still on jack stands, torque all fasteners in the following order: upper strut mount fasteners to specification, lower strut-to-knuckle bolts to specification, lower ball joint retaining fastener to specification, tie rod end retaining nut to specification, and brake caliper mounting bolts to specification. Fasteners passing through rubber bushings (control arm/strut mount pivots) MUST receive final torque with the suspension loaded to normal ride height, not hanging on jack stands; lower the vehicle or support the knuckle to simulate ride height before final torque.
15. 15

    Reconnect ABS sensor and reinstall wheels
    Reconnect the ABS wheel speed sensor electrical connector ensuring it clicks into place. Secure the sensor wiring in all original routing clips. Reinstall any strut tower covers or trim removed in step 1. Install the front wheels and thread lug nuts by hand. Lower the vehicle to the ground. Torque the wheel lug nuts to factory specification in a star/crisscross pattern (verify fastener type and exact value against the factory service manual). Note: Torque the wheel fasteners (bolts or nuts as equipped) to the factory specification in a star pattern.

Reassembly

1. Torque specifications are critical for this repair. Consult a factory service manual or reliable database for exact values as none are provided in the current database
2. All self-locking nuts (upper strut mount, ball joint hardware) should be replaced with new OEM fasteners
3. Suspension bushings and mounts should be torqued with the suspension loaded to normal ride height to prevent premature bushing failure

Verification

• Before test driving, pump the brake pedal several times to ensure proper brake caliper piston position and firm pedal feel
• Perform a careful visual inspection of all installed fasteners to verify proper torque and seating
• Test drive the vehicle at low speed in a safe area, checking for unusual noises, steering response, and brake function
• The vehicle MUST receive a professional four-wheel alignment after this repair. Suspension geometry will be significantly altered
• After 50-100 miles of driving, re-torque all suspension fasteners as settling may occur
• Verify no ABS warning lights are illuminated after test drive

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