Ball Joint - Upper

This procedure covers the removal and replacement of the upper ball joint on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, requiring suspension component disassembly and precision torque specifications.

Warnings

Tools required

Parts

• Upper ball joint × 1 — Use OEM specification
• Cotter pin for ball joint nut × 1 — Use OEM specification
• Pinch bolt (new required) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Lift front of vehicle and support securely on jack stands at manufacturer lift points
4. Remove wheel completely
5. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes
6. Inspect upper ball joint for wear, play, and torn boots to confirm replacement necessity

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connection at the upper control arm. Hold the shaft with an Allen key to prevent rotation, then remove the sway bar link nut. Disconnect the link from the control arm and secure it out of the way with wire or zip tie to prevent damage.
   Torque spec

   Sway Bar Link64 Nm (47 lb-ft)
2. 2

   Support the knuckle assembly
   Position a floor jack under the lower control arm or knuckle assembly to support the weight and maintain suspension geometry. Apply slight upward pressure but do not lift the vehicle further. This prevents the assembly from dropping when the ball joint is disconnected.
   ⚠Maintain jack support throughout the entire procedure to prevent sudden suspension movement.
3. 3

   Remove ball joint cotter pin and nut
   Straighten and remove the cotter pin from the ball joint castle nut using a punch and pliers. Discard the old cotter pin. Remove the castle nut from the ball joint stud. Do not reuse this nut if it shows wear or thread damage.
   Torque spec

   Ball Joint Nut92 Nm (68 lb-ft)
4. 4

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the upper ball joint taper from the steering knuckle. Position the tool between the control arm and knuckle, then apply force to break the taper fit. If using a pickle fork, be aware this may damage the ball joint boot (acceptable if replacing). Alternatively, strike the knuckle boss with a hammer while applying upward pressure to shock the taper loose.
   ⚠Do not strike the ball joint stud directly as this can damage the threads and prevent nut installation.
5. 5

   Remove upper control arm mounting bolts if necessary
   If the ball joint is pressed into the upper control arm and requires removal of the entire arm for pressing operations, remove the control arm mounting bolts from the frame. Mark the bolt positions or take photos for reassembly reference. Support the control arm as you remove the final bolt.
   ℹ️Some upper ball joints can be replaced with the control arm still mounted. Consult service information for your specific design.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove old ball joint from control arm
   Using a ball joint press or C-clamp press kit with appropriate adapters, press the old ball joint out of the control arm. Position the receiving cup to support the control arm around the ball joint bore, and use the pressing adapter to push the ball joint through. Apply steady, even pressure. Clean the ball joint bore thoroughly with a wire brush and inspect for damage or distortion.
   ⚠Ensure press adapters are properly sized and aligned to prevent control arm damage during pressing operation.
7. 7

   Install new ball joint
   Position the new ball joint in the control arm bore with the stud oriented correctly (typically downward toward knuckle). Using the ball joint press, carefully press the new ball joint into the control arm until it is fully seated. The ball joint should be flush with the control arm or seated to the depth specified by the manufacturer. Do not use excessive force that could damage the housing.
   ℹ️Some ball joints have a snap ring or retention clip that must be installed after pressing. Verify your specific ball joint design.
8. 8

   Reinstall upper control arm to frame
   If the control arm was removed, position it back to the frame mounting points and install the control arm bolts finger-tight. Do not torque these bolts yet, as they must be torqued with vehicle weight on the wheels to prevent bushing bind.
   ⚠Control arm bolts are only snugged at this stage. Final torque occurs after vehicle is lowered.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
9. 9

   Connect ball joint to steering knuckle
   With the jack supporting the knuckle, align the ball joint stud with the knuckle taper hole. You may need to manipulate the knuckle or raise/lower the jack slightly to align the components. Insert the ball joint stud fully into the knuckle taper. Install the new castle nut and tighten to specification. The nut slots must align with the stud hole for cotter pin installation. If needed, tighten (never loosen) the nut further to achieve alignment.
   ⚠Never loosen the ball joint nut to align cotter pin holes. Only tighten further to next slot if needed.
   Torque spec

   Ball Joint Nut92 Nm (68 lb-ft)
10. 10

    Install new cotter pin
    Insert a new cotter pin through the castle nut slots and ball joint stud hole. Bend the cotter pin legs in opposite directions (one up, one down or both around the nut) to secure it properly. The cotter pin must not interfere with suspension movement or contact other components.
    Torque spec

    Ball Joint Nut92 Nm (68 lb-ft)
11. 11

    Reconnect sway bar link
    Position the sway bar link back to the upper control arm mounting point. Install the sway bar link nut, holding the shaft with an Allen key to prevent rotation while tightening. Torque the nut to specification.
    Torque spec

    Sway Bar Link64 Nm (47 lb-ft)
12. 12

    Reinstall wheel and lower vehicle
    Install the wheel and hand-tighten all lug nuts in a star pattern. Carefully lower the vehicle until the tires just touch the ground but the full weight is not yet on the suspension. Torque the wheel lug nuts to specification in a star pattern. Then fully lower the vehicle to the ground.
    Torque spec

    Wheel Lug Nuts142 Nm (105 lb-ft)
13. 13

    Final torque control arm bolts with vehicle at ride height
    With the vehicle fully on the ground at normal ride height, torque the upper control arm mounting bolts to specification. This critical step must be performed with vehicle weight on the wheels to properly preload the control arm bushings. Failure to do this will cause premature bushing failure and suspension noise.
    ⚠This is the most critical torque step. Control arm bushings must be torqued at ride height or they will fail prematurely.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Remove jack stands and lower vehicle completely
2. Verify all fasteners are properly torqued per specifications
3. Double-check cotter pin installation and security
4. Test drive vehicle at low speed in safe area to verify no unusual noises or handling issues

Verification

• Visually inspect ball joint installation to ensure it is fully seated in control arm
• Verify cotter pin is properly installed and secured through castle nut
• Check that all suspension components move freely without binding
• Perform bounce test at each corner to ensure suspension operates normally
• Schedule wheel alignment immediately after completion as suspension geometry has been altered
• After first 50-100 miles, re-check all torque specifications and cotter pin security
• Listen for any clunking, popping, or unusual noises during test drive that might indicate improper installation

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