Axle Seal - Front

Replace the front axle seal on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD to prevent differential fluid leaks at the axle shaft interface.

Warnings

Tools required

Parts

• Front axle shaft seal × 1 — Use OEM Maserati specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification if reusable gasket is damaged
• Axle nut cotter pin or staking hardware × 1 — As specified by OEM

Fluids

• 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Raise front of vehicle and support on jack stands at manufacturer-specified lift points
4. Remove front wheel on the side requiring seal replacement
5. Verify you have the correct replacement seal for your specific axle configuration

Procedure

1. 1

   Remove axle nut and brake components
   Have an assistant apply brakes or use a suitable holding tool to prevent hub rotation. Remove and discard the axle nut cotter pin or staking. Use a breaker bar to loosen the axle nut. Remove the brake caliper mounting bolts and secure caliper out of the way without straining brake hose. Remove brake rotor.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
2. 2

   Disconnect CV joint from differential
   Locate the CV joint bolts connecting the inner CV joint to the differential output flange. Clean area around bolts to prevent contamination. Remove all CV joint bolts while supporting the axle shaft. Mark orientation of CV joint to flange for reassembly alignment if not already indexed.
   ⚠Some differential fluid may drain when CV joint is disconnected. Have drain pan positioned
   Torque spec

   CV Joint Bolts64 Nm (47 lb-ft)
3. 3

   Remove axle shaft assembly
   With CV joint disconnected from differential, remove the axle nut completely from the wheel hub end. Pull the outer stub shaft from the wheel hub using even pressure. If stuck, use a brass drift to tap on the inner end while pulling outward on the hub. Carefully remove the entire axle shaft assembly from the vehicle.
4. 4

   Drain differential fluid
   Position drain pan under differential. Remove the differential cover bolts in a crisscross pattern to prevent warping. Carefully pry cover loose and allow all gear oil to drain into pan. Remove cover completely and set aside. Inspect gasket and cover for damage.
   ⚠Fluid may rush out when cover is loosened. Keep hands clear of drain stream
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
5. 5

   Remove old axle seal
   Clean the area around the axle seal thoroughly with parts cleaner. Using the axle seal puller or slide hammer with seal puller attachment, carefully extract the old seal from the differential housing. Take care not to damage the seal bore surface. If seal is stubborn, work puller around seal circumference to extract evenly.
   ⚠Do not use sharp tools or excessive force that could score the seal bore. Any damage to bore surface will cause new seal to leak
6. 6

   Prepare seal bore and install new seal
   Thoroughly clean the seal bore with parts cleaner and inspect for scratches, burrs, or damage. Clean the axle shaft sealing surface and inspect for wear grooves or damage that could compromise seal. Lightly coat new seal outer diameter with gear oil. Coat seal lip with gear oil. Position new seal squarely in bore with spring side facing inward toward differential. Using seal driver or appropriately sized socket, drive seal evenly into bore until fully seated and flush with housing face.
7. 7

   Reinstall differential cover
   Clean all gasket surfaces on differential housing and cover thoroughly. Remove all old gasket material and RTV residue. Install new gasket or apply appropriate RTV sealant per manufacturer specifications if using formed-in-place gasket. Position cover and install all differential cover bolts finger tight. Torque bolts in a crisscross pattern to specified value.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
8. 8

   Refill differential with gear oil
   Using differential fluid pump, refill differential through fill hole with 75W-140 synthetic gear oil until fluid reaches bottom of fill hole and begins to seep out. Install and tighten fill plug. Total capacity is approximately 2 quarts but fill to level, not by volume.
9. 9

   Reinstall axle shaft assembly
   Inspect axle shaft CV joint boots for damage and ensure CV joint splines are clean. Apply thin coat of gear oil to axle seal lip area where shaft will pass through. Carefully insert outer stub shaft into wheel hub, ensuring splines engage properly. Guide inner CV joint toward differential output flange, aligning marks made during removal or factory alignment marks.
10. 10

    Connect CV joint to differential and install axle nut
    Align CV joint bolt holes with differential output flange. Install all CV joint bolts and torque to specification in a crisscross pattern. Install axle nut on outer stub shaft and torque to specification. Install new cotter pin through castle nut and bend ends to secure, or properly stake nut per manufacturer requirements.
    ⚠Never reuse old cotter pin or rely on previously staked nut. Axle nut failure can cause wheel separation
    Torque spec

    CV Joint Bolts64 Nm (47 lb-ft)

    Axle Nut250 Nm (184 lb-ft)
11. 11

    Reinstall brake components and wheel
    Reinstall brake rotor onto hub. Position brake caliper over rotor and install mounting bolts, torquing to specification. Install wheel and hand-tighten lug nuts in star pattern. Lower vehicle until tire just touches ground to prevent rotation. Torque wheel lug nuts in star pattern to specification. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification before test drive
2. Verify no differential fluid leaks around cover or new axle seal after installation
3. If axle nut uses staking method instead of cotter pin, ensure staking is properly formed into shaft groove

Verification

• Start vehicle and check for any unusual noises from differential or axle area
• Test drive vehicle at low speed and verify smooth operation without vibration or clicking from CV joint
• After test drive, recheck differential fluid level when vehicle is on level ground. Top off if necessary
• Inspect axle seal area and differential cover for any signs of fluid leakage
• Recheck wheel lug nut torque after 50-100 miles of driving

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