Transmission Rebuild - Automatic

Complete removal, disassembly, inspection, rebuilding, and reinstallation of the ZF 8HP automatic transmission in the 2017 Maserati Levante 3.0L V6 Twin Turbo RWD.

Warnings

Tools required

Parts

• ZF 8HP rebuild kit with clutches and seals × 1 — Use OEM specification
• Transmission filter kit × 1 — Use OEM specification
• Mechatronic sleeve assembly (if worn) × 1 — Use OEM specification
• Torque converter seal × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Drain plug crush washer × 1 — Use OEM specification
• Flywheel bolts if TTY × 6 — Use OEM specification
• Output shaft seal × 1 — Use OEM specification
• Input shaft seal × 1 — Use OEM specification
• Valve body gaskets and seals × 1 — Use OEM specification
• Snap rings (assorted) × 1 — Use OEM specification
• New transmission mounting bolts × 8 — Use OEM specification

Fluids

• ZF Lifeguard 8 — 10 qt

Preparation

1. Raise vehicle on lift and secure with jack stands rated for vehicle weight
2. Disconnect negative battery cable and wait 15 minutes for system capacitor discharge
3. Remove exhaust system from catalytic converters back to allow driveshaft clearance
4. Remove driveshaft and mark yoke-to-flange orientation for reassembly alignment
5. Drain transmission fluid completely using drain plug with new crush washer
6. Install engine support fixture across engine bay or attach hoist to engine lift points
7. Remove transmission crossmember and heat shields
8. Disconnect all electrical connectors from transmission including mechatronic unit, speed sensors, and range selector
9. Disconnect transmission cooler lines and plug to prevent contamination
10. Prepare clean assembly area with lint-free mats and organize parts storage containers
11. Review ZF 8HP service manual for clutch clearance specifications and end play measurements

Procedure

1. 1

   Remove transmission from vehicle
   Support transmission with transmission jack positioned at pan rails. Remove bellhousing mounting bolts working from top and bottom access points. Carefully separate transmission from engine ensuring torque converter remains fully seated on transmission input shaft. Lower transmission slowly while monitoring clearance from chassis and steering components. Mark torque converter orientation to flexplate before removal.
   Torque spec

   Mounting Bolts64 Nm (47 lb-ft)
2. 2

   Remove external components and torque converter
   Place transmission on work stand with pan facing up. Remove transmission pan bolts in criss-cross pattern and remove pan with gasket. Remove filter assembly and discard. Remove valve body cover screws and carefully lift mechatronic unit away from valve body, supporting harness. Remove torque converter by pulling straight out from input shaft. Inspect converter for debris in fluid and check for end play.
   Torque spec

   Pan Bolts18 Nm (13 lb-ft)

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Remove valve body and pump assembly
   Disconnect remaining internal harness connections from valve body. Remove valve body mounting bolts in sequence (consult manual for specific pattern). Carefully lift valve body assembly straight up to prevent damage to separator plate. Remove separator plate and gaskets, noting orientation. Remove oil pump bolts and use plastic pry tools to separate pump housing from case. Check pump gear clearances with feeler gauges.
4. 4

   Disassemble clutch packs and planetary gear sets
   Remove large snap ring retaining clutch pack assembly. Use clutch pack compressor to relieve spring pressure on clutch packs A, B, C, D, and E. Remove snap rings and carefully extract each clutch pack in order, keeping components organized by pack designation. Measure clutch plate thickness and steel plate flatness with micrometer. Remove planetary gear sets and inspect bearings, thrust washers, and gear teeth for wear. Measure end play on all rotating assemblies with dial indicator.
5. 5

   Remove shafts and inspect case
   Remove input shaft assembly by pulling straight out after removing retaining snap ring. Remove output shaft assembly in similar manner. Inspect all bearing bores in case for scoring or wear using telescoping bore gauge. Check case for cracks especially around bolt holes and mounting ears. Inspect parking pawl mechanism and return spring. Remove and inspect all one-way clutches for wear and proper operation.
6. 6

   Clean all components thoroughly
   Clean transmission case, pump housing, valve body, and all hard parts in solvent tank or parts washer. Use compressed air to blow out all oil passages in case and components. Inspect all fluid passages for blockages or debris. Clean mechatronic sleeve thoroughly and inspect for wear or scoring. Replace if any damage found. Dry all parts with compressed air and lint-free towels. Never use shop rags that can leave fibers.
   ⚠Do not submerge mechatronic unit in solvent. Clean only with approved electronic cleaner spray.
7. 7

   Install new bearings and seals in case
   Install new input and output shaft seals using seal driver from ZF tool set, ensuring square installation. Install new bushings in case if worn beyond specification. Install new thrust bearings with correct orientation (oil grooves facing proper direction per manual). Lubricate all new seals with ZF Lifeguard 8 before installation. Install new parking pawl components if worn.
8. 8

   Reassemble clutch packs with new friction plates
   Soak new friction plates in ZF Lifeguard 8 for minimum 30 minutes before assembly. Inspect all steel plates for flatness and heat discoloration, replace as needed. Assemble clutch packs per manual specifications alternating friction and steel plates. Install wave springs and pressure plates. Measure clutch pack clearances with feeler gauge and shim to specification (typically 1.2-1.8mm depending on pack). Use clutch compressor to install snap rings. Verify clearances after snap ring installation.
9. 9

   Install shafts and planetary gear sets
   Lubricate all thrust washers and bearings with assembly lube. Install output shaft into case ensuring proper engagement with parking gear. Install planetary gear sets in correct order with proper orientation of sun gears and carriers. Install input shaft assembly ensuring all splines engage properly. Check end play on each shaft with dial indicator (typically 0.2-0.8mm specification range). Install retaining snap rings ensuring they seat fully in grooves.
10. 10

    Install assembled clutch packs
    Install clutch pack assemblies into case in reverse order of removal. Ensure proper orientation and that all splines engage correctly. Verify each clutch pack seats fully and rotates freely. Install large retaining snap ring using snap ring pliers. Double-check all snap rings are fully seated in grooves. Rotate input shaft to verify no binding throughout range of motion.
11. 11

    Install pump assembly
    Install new pump seal and gasket. Position oil pump assembly onto case ensuring alignment pins engage properly. Install pump bolts and torque in star pattern to prevent warpage. Verify pump gears rotate freely after installation. Install new pump seal on input shaft side. Check input shaft end play through pump opening with dial indicator to verify correct shimming.
12. 12

    Install valve body and mechatronic unit
    Install new separator plate gaskets on case. Position separator plate ensuring all holes align with case passages. Install valve body assembly carefully ensuring manual valve engages properly with range selector linkage. Install valve body bolts finger tight then torque in specified sequence. Install mechatronic unit onto valve body ensuring sleeve engages properly. Connect all internal harness connections. Install new mechatronic cover gasket and torque cover screws evenly.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
13. 13

    Install filter and transmission pan
    Install new filter assembly ensuring proper seating on valve body. Install new transmission pan gasket (do not use RTV unless specified). Position pan and install bolts finger tight. Torque pan bolts in criss-cross pattern starting from center working outward to prevent gasket distortion. Verify no leaks around pan edge. Install fill plug with new washer and torque to specification.
    Torque spec

    Pan Bolts18 Nm (13 lb-ft)

    Fill Plug35 Nm (26 lb-ft)
14. 14

    Install torque converter and reinstall transmission
    Lubricate torque converter hub with assembly lube. Install torque converter onto input shaft ensuring it seats through three distinct stages (feel for clicks). Verify converter is fully seated by measuring distance from bellhousing face to converter ear (should be approximately 20mm). Position transmission on jack and raise into position. Install mounting bolts finger tight ensuring proper alignment. Torque mounting bolts to specification in star pattern. Reconnect cooler lines, electrical connectors, and range selector linkage.
    Torque spec

    Mounting Bolts64 Nm (47 lb-ft)
15. 15

    Install flexplate to torque converter connection
    Rotate engine to access flexplate bolts through starter opening. Align torque converter to flexplate using alignment marks made during disassembly. Install flywheel bolts (use new bolts if TTY type) and torque in star pattern to specification. Verify converter can still rotate freely after bolts are torqued. Install driveshaft with alignment marks matched. Reinstall exhaust system and heat shields.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

Reassembly

1. Fill transmission with exactly 10 quarts of ZF Lifeguard 8 fluid through fill port
2. Install crossmember and torque mounting fasteners to specification
3. Reconnect battery negative cable and clear any stored fault codes with diagnostic scanner
4. Verify proper installation of all sensors and electrical connectors with continuity test

Verification

• Start engine and verify no fluid leaks from pan, cooler lines, or seals with transmission in Park
• Check transmission fluid level using dipstick or level plug with transmission at operating temperature (80°C minimum)
• Perform shift quality test by shifting through all gears with vehicle stationary, verifying clean engagement
• Road test vehicle through all gear ranges verifying smooth shifts under light and moderate throttle
• Scan for transmission fault codes after test drive and verify none are present
• Check fluid level again after test drive and top off if necessary to proper level
• Verify no whining, grinding, or abnormal noises in any gear or during shifts
• Confirm torque converter lockup engages properly at cruise speeds without shudder
• Recheck all mounting bolts and cooler line connections for proper torque after test drive

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle