Brake Caliper Bracket

Replace the brake caliper bracket on a 2017 Maserati Levante 3.0L V6 Twin Turbo, including removal of caliper, bracket installation, and brake system bleeding.

Warnings

Tools required

Parts

• Brake caliper bracket × 1 — Use OEM specification
• Copper crush washers for banjo bolt × 2 — Use OEM specification
• Brake pad anti-rattle clips (if damaged) × 1 — Use OEM specification

Fluids

• DOT 4 Racing Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts 1/4 turn while vehicle is on ground
3. Raise vehicle with floor jack at proper jacking point and secure with jack stands
4. Remove wheel completely
5. Place catch pan under brake caliper area
6. Verify replacement bracket matches OEM part exactly before beginning disassembly
7. Have DOT 4 Racing brake fluid ready in sealed container

Procedure

1. 1

   Remove brake caliper
   Locate the caliper mounting bolts (typically on the back of the caliper). Use an 18mm wrench to remove both caliper bolts. Support the caliper weight as you remove the second bolt. Do NOT let the caliper hang by the brake hose.
   Torque spec

   Caliper Bolts92 Nm (68 lb-ft)
2. 2

   Support caliper assembly
   Carefully lift the caliper with brake pads off the rotor. Use a caliper hanger or sturdy wire to suspend the caliper from the suspension or chassis. Ensure no strain is placed on the brake hose. Do not disconnect the brake line at this stage unless the caliper is also being replaced.
   ⚠Never allow the brake caliper to hang by the brake hose. This can damage the hose internally and cause brake failure.
3. 3

   Disconnect brake hose (if necessary)
   If replacing the bracket requires brake line disconnection, place catch pan directly under banjo bolt. Using a line wrench, carefully loosen and remove the brake hose banjo bolt from the caliper. Allow fluid to drain into catch pan. Cap or plug the brake line immediately to prevent contamination and further fluid loss. Discard old copper crush washers.
   ⚠Brake fluid will drain when line is disconnected. Keep away from painted surfaces and immediately wipe up spills.
   Torque spec

   Brake Hose Banjo Bolt43 Nm (32 lb-ft)
4. 4

   Remove caliper bracket bolts
   Identify the two caliper bracket bolts that secure the bracket to the steering knuckle or axle housing. These are larger bolts behind the rotor area. Use a 19mm socket and breaker bar if needed to loosen the bracket bolts. Remove both bolts completely and keep for comparison with new hardware if provided.
   Torque spec

   Bracket Bolts107 Nm (79 lb-ft)
5. 5

   Remove old caliper bracket
   Pull the caliper bracket straight off the mounting surface. Remove the brake pads and any anti-rattle clips or shims from the old bracket. Inspect the rotor surface for damage, scoring, or excessive wear. Check brake pad thickness to determine if replacement is needed during reassembly.
   ℹ️This is an ideal time to inspect and measure the brake rotor. If rotor thickness is below minimum specification or shows deep scoring, it should be replaced.
6. 6

   Clean mounting surfaces
   Use a wire brush to thoroughly clean the bracket mounting surfaces on the steering knuckle or axle housing. Remove all rust, corrosion, and old thread locker from bolt holes. Clean the bolt threads with a wire brush. Spray mounting surfaces with brake cleaner and wipe dry. Ensure mating surfaces are clean and flat.
   ⚠Do not use compressed air to blow brake dust. Use brake cleaner spray and wipe with disposable towels.
7. 7

   Install new caliper bracket
   Transfer anti-rattle clips and pad shims to the new bracket if not pre-installed. Position the new caliper bracket onto the mounting surface, aligning bolt holes carefully. Insert both bracket bolts by hand and thread several turns to ensure proper engagement. Apply medium-strength thread locker to bracket bolt threads as recommended.
   Torque spec

   Bracket Bolts107 Nm (79 lb-ft)
8. 8

   Torque bracket bolts to specification
   Using a calibrated torque wrench, tighten the front caliper bracket bolts to exactly 120 Nm (88 lb-ft) in an alternating pattern. Tighten one bolt to 50%, then the other to 50%, then return to first bolt for final torque, then final torque on second bolt. Verify both bolts are fully seated and torqued correctly.
   ⚠️CRITICAL: Under-torqued bracket bolts can allow the bracket to shift or detach under braking, causing complete brake failure. Over-torquing can strip threads or break bolts. Use a calibrated torque wrench.
   Torque spec

   Bracket Bolts107 Nm (79 lb-ft)
9. 9

   Install brake pads
   If installing new brake pads, apply a thin layer of silicone brake grease to the pad backing plate contact points on the bracket (NOT on friction material or rotor). Install anti-rattle clips if equipped. Slide brake pads into position in the caliper bracket. Ensure pads move freely but without excessive play.
   ⚠Never apply grease or lubricant to brake pad friction material or rotor surfaces. This will cause brake failure.
10. 10

    Compress caliper piston
    Before reinstalling the caliper, the piston must be compressed to accommodate new or existing brake pads. Use a C-clamp or brake piston tool to slowly compress the piston(s) fully into the caliper bore. This will push brake fluid back into the master cylinder reservoir. Monitor the brake fluid reservoir and remove fluid if necessary to prevent overflow.
    ⚠Compressing the piston will raise brake fluid level in the reservoir. Check reservoir and remove excess fluid if needed to prevent overflow and paint damage.
11. 11

    Reconnect brake hose (if disconnected)
    If the brake line was disconnected, install NEW copper crush washers on both sides of the banjo fitting. Position the banjo bolt through the brake hose fitting and into the caliper. Hand-thread the banjo bolt, then torque to exactly 43 Nm (32 lb-ft) using a torque wrench.
    ⚠️CRITICAL: Always use new copper crush washers. Reusing old washers will cause brake fluid leaks and potential brake system failure.
    Torque spec

    Brake Hose Banjo Bolt43 Nm (32 lb-ft)
12. 12

    Reinstall brake caliper
    Remove caliper from hanger or support wire. If caliper slide pins were removed, apply silicone brake grease to pin surfaces before reinstallation. Position caliper over brake pads and align mounting bolt holes. Apply medium-strength thread locker to caliper bolt threads. Insert and hand-thread both caliper bolts.
    Torque spec

    Caliper Bolts92 Nm (68 lb-ft)

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
13. 13

    Torque caliper bolts
    Using a calibrated torque wrench, tighten caliper mounting bolts to exactly 92 Nm (68 lb-ft). Verify both bolts are properly seated. Check that caliper is centered over rotor and moves freely if equipped with sliding mechanism.
    ⚠️CRITICAL: Improperly torqued caliper bolts can allow caliper movement or detachment during braking, causing brake failure and loss of vehicle control.
    Torque spec

    Caliper Bolts92 Nm (68 lb-ft)
14. 14

    Bleed brake system
    If the brake line was disconnected, the system MUST be bled to remove air. Locate the brake bleeder screw on the caliper. Attach a clear hose to the bleeder and route into a catch container. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open bleeder screw 1/4 turn, allow fluid and air to escape until flow stops, then close bleeder before pedal reaches floor. Repeat until no air bubbles appear and only clean brake fluid flows. Torque bleeder screw to 10 Nm (7 lb-ft).
    ⚠️CRITICAL: Air in brake lines will cause brake pedal to feel soft or go to the floor, resulting in inadequate braking force. Bleeding must be thorough and complete.
    ⚠Do not overtighten bleeder screw. The specified torque is only 10 Nm (7 lb-ft). Overtightening will strip threads or break the bleeder.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
15. 15

    Reinstall wheel and final checks
    Clean wheel mounting surface on hub. Install wheel and hand-thread all lug nuts. Lower vehicle until tire just contacts ground. Torque wheel lug nuts to 140 Nm (103 lb-ft) in a star pattern. Fully lower vehicle and remove jack stands. Check brake fluid reservoir level and top off with DOT 4 Racing brake fluid to proper level.
    ⚠️CRITICAL: Before moving vehicle, pump brake pedal multiple times until pedal feels firm and normal. Test brakes at low speed in a safe area before returning to normal driving.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reassembly is included in the procedure steps above
2. Ensure all torque specifications are met exactly as specified
3. Replace copper crush washers whenever brake line connections are opened
4. Apply thread locker to bracket and caliper bolts as specified
5. Bleed brake system completely if brake line was disconnected

Verification

• With engine off, pump brake pedal repeatedly. Pedal should become firm and hold pressure. If pedal is soft or spongy, air remains in system and further bleeding is required
• Inspect all connections for brake fluid leaks. Check banjo bolt, bleeder screw, and any line fittings
• Check brake fluid reservoir level. Top off to MAX line with fresh DOT 4 Racing brake fluid
• Start engine and verify brake warning light is off
• Test brakes at low speed (under 10 mph) in a safe area. Verify firm pedal feel and adequate stopping power
• Perform several moderate stops from 25-30 mph in a safe area to verify proper brake operation
• After 50-100 miles, re-check all bolt torques and inspect for fluid leaks
• If brake pedal feels abnormal, pulsates, or if stopping distance seems excessive, discontinue driving and seek professional service immediately

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