Ball Joints - Upper and Lower

Complete replacement of upper and lower ball joints on the front suspension of a 2017 Maserati Levante, including disconnection of suspension components and torquing to specification.

Warnings

Tools required

Parts

• Upper ball joint (per side) × 2 — Use OEM specification
• Lower ball joint (per side) × 2 — Use OEM specification
• Cotter pins × 4 — Use OEM specification
• Pinch bolts (if reusable bolts damaged) × 2 — 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. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
4. Remove both front wheels completely
5. Apply penetrating oil to all ball joint nuts, pinch bolts, and suspension fasteners; allow to soak for 15 minutes
6. Photograph or mark suspension component positions for reference during reassembly

Procedure

1. 1

   Disconnect sway bar link
   Remove the sway bar link from the control arm or strut assembly. Hold the shaft with an Allen key to prevent spinning while loosening the nut. This provides clearance for control arm removal.
   Torque spec

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

   Remove upper ball joint cotter pin and nut
   Straighten and remove the cotter pin from the upper ball joint castle nut. Using a socket and breaker bar, remove the ball joint nut but do not completely separate the joint yet. Leave the nut threaded on a few turns to protect the threads.
   Torque spec

   Ball Joint Nut92 Nm (68 lb-ft)
3. 3

   Separate upper ball joint from knuckle
   Using a ball joint separator or pickle fork, carefully separate the upper ball joint taper from the steering knuckle. Apply force gradually to avoid damaging the knuckle or surrounding components. Once separated, remove the castle nut completely and support the knuckle to prevent strain on brake lines.
   ⚠Ball joint separator tools can slip suddenly. Ensure proper positioning and maintain control during separation.
4. 4

   Remove lower ball joint cotter pin and nut
   Locate the lower ball joint connection to the steering knuckle. Straighten and remove the cotter pin, then remove the castle nut. Leave the nut threaded on a few turns initially for safety.
   Torque spec

   Ball Joint Nut92 Nm (68 lb-ft)
5. 5

   Separate lower ball joint from knuckle
   Use the ball joint separator to break the taper connection between the lower ball joint and steering knuckle. Apply steady pressure until the joint releases. Remove the castle nut completely. The knuckle assembly should now be free from both ball joints.
   ⚠Support the steering knuckle and brake assembly to prevent damage to brake lines and ABS sensors.
6. 6

   Remove upper ball joint from control arm
   The upper ball joint is typically pressed or bolted into the upper control arm. If pressed, use a ball joint press kit to carefully press out the old ball joint from the control arm. If bolted, remove the mounting bolts. Clean the control arm bore thoroughly with a wire brush, removing any rust or debris.
   ℹ️Inspect control arm bore for damage or excessive wear. Replace control arm if bore is damaged or oversized.
7. 7

   Install new upper ball joint
   Position the new upper ball joint in the control arm bore, ensuring proper orientation (grease fitting accessible). Use the ball joint press to install the new joint, pressing until fully seated. Verify the joint is flush and properly seated in the control arm. If bolted type, install new bolts and torque to specification per service manual.
8. 8

   Remove lower ball joint from control arm
   Similar to the upper ball joint, press or unbolt the lower ball joint from the lower control arm. Use the ball joint press kit with appropriate adapters to press out the old joint. Clean the control arm bore thoroughly, removing all contamination.
9. 9

   Install new lower ball joint
   Install the new lower ball joint into the lower control arm using the ball joint press. Ensure correct orientation with grease fitting accessible. Press until the joint is fully seated and flush with the control arm. Verify proper installation by checking for any movement or looseness.
10. 10

    Reconnect steering knuckle to ball joints
    Position the steering knuckle so both upper and lower ball joint studs can be inserted into their respective holes in the knuckle. You may need to use a pry bar or jack to align components. Install the castle nuts on both ball joints but do not torque yet. Thread them until snug to hold the assembly together.
11. 11

    Torque ball joint nuts and install cotter pins
    Using a calibrated torque wrench, torque both upper and lower ball joint castle nuts to 92 Nm (68 lb-ft). The castle nut slots must align with the cotter pin hole in the stud. If necessary, tighten slightly beyond torque spec (never loosen) to align slots. Install new cotter pins through the stud holes and bend the ends to secure.
    ⚠Never loosen a castle nut to align cotter pin holes. Only tighten further if needed for alignment.
    Torque spec

    Ball Joint Nut92 Nm (68 lb-ft)
12. 12

    Reconnect sway bar link
    Reattach the sway bar link to the control arm or strut assembly. Hold the shaft with an Allen key while torquing the nut to 55 Nm (41 lb-ft). Ensure the link is properly seated and not binding.
    Torque spec

    Sway Bar Link64 Nm (47 lb-ft)
13. 13

    Install wheels and perform initial torque
    Mount the front wheels and hand-tighten the lug nuts. Lower the vehicle until the tires just contact the ground but suspension is not fully loaded. Torque wheel lug nuts to 142 Nm (105 lb-ft) in a star pattern.
    Torque spec

    Wheel Lug Nuts142 Nm (105 lb-ft)
14. 14

    Final suspension torque with vehicle weight
    Fully lower the vehicle so that the suspension is at normal ride height with vehicle weight on the wheels. If control arm bolts were loosened during the repair, torque them to 165 Nm (122 lb-ft) with the vehicle at ride height. This ensures proper bushing alignment and longevity.
    ℹ️Control arm and subframe bolts must be torqued at ride height to prevent premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Verify all fasteners are properly torqued and cotter pins are installed on all ball joints
2. Check that brake lines and ABS sensors were not damaged during the procedure
3. Perform a visual inspection of all suspension components for proper installation

Verification

• Test drive vehicle at low speed in a safe area, listening for any unusual noises or clunking from the suspension
• Check for proper steering response and no pulling to either side
• Schedule a professional four-wheel alignment immediately after this repair
• After alignment, re-check all torque specifications to ensure nothing loosened during alignment procedure
• Inspect ball joint boots for proper seating and no tears or damage

More procedures for this vehicle