Morgan Aero

A whistling noise comes from the engine and this can be traced to the design of air filter box. A new one is being designed as well and will be retrofited to the car under warranty in Spring 2010. The interim solution is to wait for the next service (as the wings must be taken off obtain access to the box9 and drill some holes in the plastic cover to allow more airflow.

Battery Replacement (Series I)

The original Red Flash 750 battery, used on Aeros and Plus 8s, has proved to be a problem for many. It is a small battery supplied under many names and originally designed and still supplied from the US for a Harley motorcycle. The wisest course would be to install a standard battery and many have done so. However, should you wish to remain with the same dimension battery, it is also available under the brand name Odyssey in all countries. Simply give the battery dealer the dimensions of your battery. http://www.odysseybatteriesonline.co.uk/ or http://www.tayna.co.uk/catalog/73/0/Motorcycle-Batteries-Odyssey-Batteries-page1.html

Bonnet Latches

Regularly examine and confirm the bonnet's latches. On occasion, some may not secure properly which can result in the bonnet flying up at high speed. Check them by the knob firmly to their closed position. If they can still detach, then they must be adjusted carefully to confirm full function. For those wanting greater assurance, a racers bonnet pin catch system can be retrofitted.

Brake Line Rupture

Thus far, reports on this issue are from Series I owners. The routing of the brake lines from the brake master cylinder makes them suceptible heat from the exhaust and catalytic converters. The lines can be damaged/melt and breached. This leads to deteriorating and/or total brake loss unless addressed.
A more detailed report and suggested fix is expected.

Car Will Not Start

Car doesn't start. At first this may occur only when driven and stopped hot. It could be that the Immobilizer is locked on. This may be caused by this unit touching the bottom of the fuse box. After the car is stopped, the resultant heat causes immobilizer malfunction and damage. The car may start working again once it cools sufficiently. However, the best solution is to go to an Aero dealer and have a new Immobilizer put in and heat wrap it. A new immobilizer will require new keys.

Car Will Not Start II

Car doesn't start when warm. Just turns without catching. You may find if you turn the ignition key on and off 3-4 times in succession in succession, it will reboots the engine's management/ignition system and the engine will then start again.

Car Will Not Start or Stalls III

Specific to Aeri Series 4 and Aeromaxes. The fuel pump fuse blows. This is the 10 amp version found in thee black square fuse box. If your 10 amp fuse works and you don't have problems, there is no absolute need to change it. However, some cars have experienced a problem, espcially on cars tthat have engine overruns. The Factory recommends a 20 amp fuse in these instances.

In the instances where a 20 amp fuse does not cure the issue, check for a short. A split in the pump wire (see at the charcoal canister) can cause an earth which will short the system and blow any fuse.

Cruise Control AEROMAX/S4

The cruise control stops working. The root cause hasn't been identified so far. (January 2010)

Doors

Aero doors, especially the earlier versions, can be misaligned. On the Aero ver. I, doors are constructed in two sections The doors on the Mk1 are built from 2 major sections. The lower door and the window frame. Unfortunately these are not always stable in relation to each other and can result in the top of the window frame pulling away from the “A” pillar. This is easily fixed but often mis-adjustment of the lower door can result in the front of the door fouling the lower “A” pillar section and eventually rubbing through the paint.

The side door glass is VERY EASY to break. The windows are a laminate of non-safety glass with a heating wire in between – try looking through them in the light and you will see the filaments. Unfortunately this makes them particularly weak and slamming the door or shutting firmly (Especially with the window part open – Not fully up or fully down) can easily result in a cracked side pane. These are £600 each!! Assuming you can find one. Many have been swapped for non heated versions and can occasionally be odd side to side.

Engine Overuns

Specific to Aero Series 4 and Aeromaxes. The engine overruns. There is a specific Factory fix for this and it is suggested your contact them or your dealer. The overrun can also lead to a fuel pump fuse issue. See here.

Flywheel BMW fault. Dual mass flywheel can require replacement after 10-15,000 miles. Spring fatigue and failure causes the flywheel to make a rattling or clunking noise when the clutch is engaged. Depressing the clutch pedal may cause the noise to go away. Debris from broken springs can also become trapped between the back of the flywheel and engine causing damage to the rear main oil seal housing and oil pan. Expensive engine out job.

Front End and Light Corrosion

The front indicator lights suffer from corrosion around the light fixing bolts. Unfortunately this is a a characteristic of Aeros and evidences electrolytic corrosion. It is usually found found round the edges of the front splitter & lower grill section and where the wings bolt on. Galvanized steel bolts were used with aluminium wings and that creates the reaction. If caught early, it can be repaired but this will become more difficult as time goes one and corrosion deepens.

Front Intake Mesh

The intake mesh on early Aero versions was often fitted under too much stress. In time the stress dislodges and/or loosens the mesh brackets and it becomes loose.

Front Splitter

The Aero front splitter is a easy target for road debris, causing scratches and multiple stone chips. This can be prevented with clear plastic adhesive covering such as Armor-Guard. Many owners prefer to leave the splitter has not been protected and that will necessitate regular repainting. I know f an owner, who has had a polished stainless cover made for the splitter and this will avoid the normal pitting.

Gearbox - Series I. The Aero Series I was designed as a street legal race car. As such it is has few of measures for driveline compliancy one fins in a normal car as the goal is to get as much immediate power down to the rear wheels withi a minimum of loss. Inevitably, this produces many noises in all drive train components, They sound like something is broken. At times, this can be true. The MMC Serivice Departmetn has suggested that this can be addreessed with a later Series set up, with more forgiveness in the uise of a rubber munted differential. However, one of the greatest features of the Series I is its instant transfer or engine power to the rear wheels and that will be lost.

Series II, III, IV Transmission noises will be experienced;

1. when coasting to a stop in 2st, 2nd or 3rd gear, with or without the clutch depressed, there is a whirring noise like a scratched ballrace or running a playing card in bicyle spokes or a shaking a box of nuits and bolts.

2. On slow- medium acceleration in 1st and 2nd there will be a chattering noise.

The MMC has a written advisory they send to owners who express concern. They state that the Aero chassis amplifies drive train noises. They are not heard on BMWs fitted with the same setup as they have stuffing that muffles these noises completely. The Aeros have little soundproofing.

Hard Tops

Experiences of those ordering retro-fit hard tops have not been good. There are numerous reports of a gap between the front edge of the top and the windscreen that allows incoming water to drip on lap or knees. It is advisable to choose this option when buying the car new or deliver the car to the Company to have them fit it. One can also try to fit window molding rubber.

Heater Fan AEROMAX/S4

There is an annoying noise coming from the heater fan. The dealers have been informed that the MMC will develope a new heater fan box that will hopefully solve the problem. It may be avaliable sometimes in Spring 2010, and exchangedfor the original under warranty.

Leak (Air) - AEROMAX

The cars can develop an air leak in the rear area and the pressure variance can cause the tail windows to open. This has been fixed using some spacers to lower the electric latches and thusly increase the pressure on the rubber joint. As well a new joint has been instelled as the older one was not folowing the contours correctly.

Leak II

The heater drain hose may have come loose. You can check by lying across the seats and looking forward along the gearbox cover. You should espy a small hose that goes from the back of cabin heater and through the bulkhead. This should be attached to the back of the heater and is the conduit for the draining moisture. If it is loose, the heater/AC will drain into the car. Re-attach the hose to the hose fitting at the back of the heater and secure it in place with a jubilee clip.

Light Corrosion

The earlier Aeros use mild steel fasteners to screw the indicator lights to the aluminum wings. This sets up an electrolytic reaction that corrodes the lights and/or the fittings in question..which can aslo effect light function. Fittings and lights should be remioved, carefully cleaned and replaced with alunimum fashteners or coated with a anti-corrosion product..

Lock Control Issue (the "Pliper")

If you change the battery of the control (the pliper) it will often not operate the lock mechansims after. The Manual does not show the solution.
Try disconnecting the car battery for a bit. Tghis allows the system to reset and often allows the pliper to work again.

Loss of Engine Power

Engine restricts RPM, and the car will not go beyond modest speed (30-40 mph).

The automobile management system believes it has detected a fault serious enough to revert to "Limp-Home-Mode" for the car or driver's protection. In this case, the ABS Brakes are sending a signal to the computer forcing the car into a safe mode due to perceived failure of the brake system. This can be cured by having the Aero dealer check the brakes thoroughly and if they check out, replace of the ABS sensors.

Power Steering Fails (Series I)

The power steering pumps are commonly known to fail on the Aero Series I and leave the driver suddenly without power assisted steering. The cure is a retrofit of the electric steering from the Aero Series II. The MMC has a modification kit to fit the newer pump at a cost of 320£.

Side Exhausts

All Aeros (Series II, III & IV) equipped with side exhaust have brackets can shear. The Company can replaced these with stronger brackets which should fix the issue. It is suggested that you confirm whether you have the original brackets and if so, warn your Aero dealer and have them replaced at your next service. N.B. It is also wise to warn passengers of the dangers of touching the side pipes. Burns have happened.

Stalling When Warm

The car keeps stalling at idle though starting, power and performance otherwise unaffected whether hot or cold.
This normally indicates a defective Mass Air Sensor. See Aero dealer for replacement. Check here as well.

Tyre pressure Indicator AEROMAX/S1/S2/S3/S4

The tyre pressure device has issues. After a period of usage, many report that it will only work occasionally after numerous resets and then it might not monitor all tyres. The system is made up of three main components, the sensors at the wheels, the display unit in the dash and the control unit. Repair is complex due to the location and fitting of the control unit. It is held in place with cable ties (S2) and could work itself loose. Once loose, vibration would cause the wiring or the power feed to detach. The unit then stops functioning or falls back on default programming.

Vapor in Cabin (AERO S3)

Under certain condtions, the cockpit can fill with vapor..coming from the air vents.

Wheel Arch Liner Detaches

The wheel arch liner can detach being held only by the bonder and the side lamp fitting. Unless addressed, the liner it will foul the exhaust.

Wheel Rims Badly Pitted and Damaged

Aero I rims were matched with tyres that allow the rim to extend beyond the tyre. This quickly ruins (sidewalk scuffing) the edges of the rims. There are two options. One can buy replacements (550£) or have the rims periodically repaired and refurbished by one of the many UK shops that specialize in this task. There are even shops that can do magnesium rims. Expect to pay between 30-45£ a rim.

Side Windows Will Not Close.

Usually this means one must reset the window computer. Lower the window on the switch until it reaches the bottom and then raise the window right to the top and hold it there in the switch "up" position for approximately for 7 seconds. The window should automatically reset. If this does not work, take the car to your nearest Aero dealer. N.B. If you disconnect the battery or press the isolator button under the bonnet the window computer will loose their setting again.

Windows Rear Glass I - AEROMAX

One opens the rear windows with the remote control and they end up on the ground, often causing some body damage. The problem is that the adhesive glue used unglues in arm temperatures. Where there is metal to glass contact, the glue heats up sufficiently to exceed the glue supplier's recommended maximum temperature. The cars should be checked with a Aero dealer and have the windows returned to the Factory to have the glue upgraded.

Follow-up: The MMC used a different supplier that solved the temperature problem. However, this glue proved to be so strong that the windows delaminate. The MMC is aware of the issue and the present plan (November 2009) is to have the two rear glass panels changed under warranty when a newer type of glue (one that can both cope with higher temperatures AND not damage the glass) is approved.

Windows Rear Glass II - AEROMAX

August 2008 The rear glass can also open under heavy rain.

VERSIONS, VARIATIONS AND LIMITED EDITIONS

General

The Aero has gone through many changes. For many years, this was on an ongoing basis and cars, even within the same Series or Limited Edition or month will not necessarily match. Therefore, this section should not be considered definitive and should only be used as a general guide.

Prototypes (1998-2001)

The company went through an extended period to settle on a concept for the first Aero Series. Many have looked back in retrospect and chosen the Big Blues as the first evidence of the Aero concept. These were two racing models generally based on the Plus 8 but with much wider bodies and a tuned 5.7 Chevrolet engine. They were the fastest of the models for more than a decade!

After the Big Blues, two prototypes were made using the BMW 4.4 engine and the early stages of what would become the early Aero chassis. As there the body shape had not been finalized, and with a desire to keep development discrete, these cars were "clothed" in a Plus 8 shape. However, though the early Aero chassis (Version 1) had Plus 8 dimensions from the bulkhead back, the BMW V8 was much too wide to use a Plus 8s front dimensions, single piece wings-and-hood were fabricated from fiberglass to cover the front. They were dubbed the "Mules".

Series I (2001-2004)

Complete with a bespoke aluminium chassis, all independent suspension and powered by a 4.4 litre MBW V8 engine producing 286 bhp at 5.500 rpm this was a radical departure from the traditionally build Morgans. Performance was 0 to 60 mph in 4.9 seconds with a top speed of 151 mph.

Series II (2005-2007)

Version 2 of the Aero 8 was designed with the US market in mind and was launched at the 2004 Los Angeles Motor Show and shown agan at the New York Auto Show in the Spring of 2005. It used the later BMW M62 V8 engine. The chassis was widened giving more cockpit area and reducing the wing expanse at the doors. Further revisions included (but were not limited to): rear suspension modifications leaving behind the patented Lawrence concept, built in compliancy throughout the driveline, a wider cockpit for more interior room (an increase of 6 inches in width), and a new larger trunk with a ducktail lid and an optional removable hardtop. With minor changes, it kept the controveral front end treatment from the Series I. The new V8 was a 4.4-liter, 330 hp with a top speed of 160 mph and a 0-60 mph of 4.8 seconds. Series 2 proved the least popular of the Aero line and was soon replaced by the Series III.

Series III (2007-2009)
Version 3 shows the first infleunces of Matthew Humphries, a stylist hired by the Company in this period. The third version of Morgan Aero 8 kept all of the engineering and structural modifications of Version 2. However, it had a completely reworked front end, (restyled front wings, lights and grill) addressed the signature cross-eyed headlight look of the S1 and S2 versions. The ducktail rear boot styling was retained.

Series IV (2009-2009)

Shaped like the Aero Version III, Version 4 of the Morgan Aero 8 saw another new engine, the old BMW 4.4 V8 valvetronic replaced with the newer BMW 4.8 V8 with 367bhp and 370 lb/ft of torque. This extra 13% power gave this version a power-to-weight ratio of 315bhp per tonne.
The front end look is now the same as the Aeromax (see below). For the first time in a century, this stock Morgan can also be had with an optional automatic transmission (that was originally planned and announced for the US market but never made it there). The company states that "ZF’s latest 6 HP26 six speed gives even better performance than a manual gearbox due to its special lock up clutch, low power loss design and instant change characteristic. The automatic is useable either as a full automatic for more relaxed driving or in sport manual mode when the bespoke gear lever will hold the engine revs up to the maximum in each gear, increase change speed and ‘blip’ the throttle to smooth down changes."
In addition to these technical changes, a repositioned fuel tank (to improve the weight distribution), revised instrumentation (from cream dials with blue numerals to black with white), an increase in luggage space, revised air vents, a move to a conventional handbrake leaver and air intakes and exits on the front wings distinguish the Series 4 Aero 8 from previous models. The ducktail rear boot was retained.
This was the last Aero 8 model. Official production ceased at the end of 2009.

AEROMAX (2008-2010)

The Aeromax was originally commissioned by Eric Sturdza, a banker and President of Switzerland's Barings Bank. This was the first Aero in which Humphries' styling influence outweighed the early designs found in the Aeros. It is a coupe, available at first with the 4.4 engine which was soon replaced by the 4.8 and the option of a manual or automatic gearbox. The rear end was radically changed from that of the Aero IV but the car remained the same under the body paneling. It was offered as a "Limited Edition" of 100 cars with an initial 25,000£ deposit against a price of £110,000 respresenting a premium of 60% over the Aero IV. The Sturdza connection proved advantgeous in another way. Barings Bank sponsored a professional racing team in 2009 and 2010. Production ceased in early 2010.

AERO S.S. (2010-