Brake Caliper - Rear

This procedure covers removal and replacement of the rear brake caliper on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including brake line disconnection, caliper removal, and system bleeding.

Warnings

Tools required

Parts

• Rear brake caliper assembly × 1 — Use OEM Brembo specification for Levante
• Copper crush washers for banjo bolt × 2 — 14mm ID banjo washer set
• Brake caliper mounting hardware kit (if corroded) × 1 — Use OEM specification

Fluids

• DOT 4 Racing Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid surface and apply parking brake firmly.
2. Place wheel chocks in front of front wheels.
3. Using turkey baster or suction tool, remove approximately half the brake fluid from master cylinder reservoir to prevent overflow during caliper removal.
4. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground.
5. Lift rear of vehicle with floor jack at designated rear jacking point and support securely on jack stands at chassis reinforcement points.
6. Remove rear wheel completely.
7. Clean the caliper, brake line connection, and mounting hardware area with brake cleaner to remove dirt and corrosion.

Procedure

1. 1

   Disconnect brake line from caliper
   Using an 18mm flare nut wrench, carefully loosen the brake line banjo bolt connecting the flexible brake hose to the caliper. Position the brake fluid catch container below the connection point. Once loose, remove the banjo bolt completely and immediately plug the brake line with a plug cap or clean rubber cap to minimize fluid loss and contamination. Note the position of the two copper crush washers (one on each side of the banjo fitting) and discard them—they must not be reused.
   ⚠Brake fluid will drain immediately upon disconnection. Position catch container carefully and work quickly to minimize fluid loss.
2. 2

   Remove caliper bracket mounting bolts
   Locate the two caliper bracket bolts that secure the entire caliper assembly to the rear knuckle/hub assembly. These are typically 17mm bolts located at the top and bottom of the caliper bracket. Using a 17mm socket and breaker bar, loosen both caliper bracket bolts. These bolts are torqued to 100 Nm and may require significant force to break free. Remove both bolts completely.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
3. 3

   Remove caliper assembly from vehicle
   With both bracket bolts removed, carefully pull the entire caliper and bracket assembly away from the brake rotor and off the hub assembly. The assembly may be heavy (Brembo calipers are substantial). Support the weight carefully and set the old caliper on a clean work surface. Inspect the mounting surfaces on the hub for corrosion or damage and clean if necessary.
4. 4

   Inspect brake rotor and mounting area
   With the caliper removed, inspect the brake rotor for excessive wear, scoring, or warping. Check the rotor minimum thickness specification if replacement is being considered. Inspect the hub mounting surface and caliper mounting points on the knuckle for corrosion, damage, or worn threads. Clean all mounting surfaces with a wire brush and brake cleaner. This is an opportune time to service or replace rotors and brake pads if needed.
5. 5

   Prepare new caliper for installation
   Unpack the new rear brake caliper and verify it matches the original (left or right side, piston count, mounting bracket configuration). Ensure the bleeder screw is present and moves freely. Remove any protective caps or shipping plugs from the brake line inlet port. Verify that brake pads are correctly installed in the new caliper bracket if it comes as a loaded assembly. If installing bare caliper, transfer pads and hardware from old unit, ensuring proper orientation.
6. 6

   Install new caliper onto hub assembly
   Position the new caliper and bracket assembly over the brake rotor, aligning the mounting holes with the threaded holes in the rear knuckle/hub assembly. If using threadlocker (recommended), apply a small amount of medium-strength threadlocker to the caliper bracket bolt threads. Insert both caliper bracket bolts and thread them in by hand to ensure proper thread engagement. Using a torque wrench and 17mm socket, tighten both bolts to exactly 100 Nm (74 lb-ft) in a cross-pattern (top then bottom, or vice versa) to ensure even seating.
   ⚠️CRITICAL: Caliper bracket bolts MUST be torqued to exactly 100 Nm. Under-torquing can result in caliper detachment during braking, causing catastrophic brake failure.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
7. 7

   Connect brake line to new caliper
   Remove the plug cap from the brake line. Install one NEW copper crush washer onto the banjo bolt, then position the brake line banjo fitting against the caliper inlet port. Install the second NEW copper crush washer on the opposite side of the banjo fitting. Insert the banjo bolt through the washers and banjo fitting and thread it into the caliper inlet port by hand. Using an 18mm flare nut wrench and torque wrench, tighten the banjo bolt to exactly 25 Nm (18 lb-ft). Do not overtighten.
   ⚠️CRITICAL: Always use NEW copper crush washers. Reused washers will not seal properly and will cause brake fluid leaks and potential brake failure.
   ⚠Do not exceed 25 Nm torque on the banjo bolt. Overtightening can strip the aluminum caliper threads or crack the banjo fitting.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
8. 8

   Bleed rear brake caliper
   Refill the master cylinder reservoir to the MAX line with fresh DOT 4 Racing brake fluid from a sealed container. Attach a clear vinyl hose to the caliper bleeder screw and place the other end in a clear container with a small amount of brake fluid. Using a 10mm wrench, open the bleeder screw 1/2 to 3/4 turn. If using a pressure bleeder, apply 15-20 PSI pressure and allow fluid to flow until all air bubbles are purged and only clean fluid emerges. If manually bleeding, have an assistant pump the brake pedal 3-5 times and hold pressure while you open the bleeder momentarily, then close it before pedal is released. Repeat until fluid runs clear without air bubbles. Close the bleeder screw to exactly 10 Nm (7 lb-ft) torque.
   ⚠Do not overtighten the bleeder screw. It is brass and easily damaged. Torque to exactly 10 Nm and no more.
   ℹ️Keep the master cylinder reservoir filled during bleeding process. Never allow it to run dry or additional air will enter the system.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
9. 9

   Complete system bleeding and pedal test
   After bleeding the replaced caliper, bleed all other calipers in the proper sequence (typically: right rear, left rear, right front, left front) to ensure complete air removal from the entire system. Top off the master cylinder reservoir to the MAX line. With the engine off, pump the brake pedal firmly 10-15 times. The pedal should become firm and not sink to the floor. Check all connections for leaks, particularly the banjo bolt connection at the new caliper. Wipe down any spilled brake fluid immediately.
   ⚠️A soft or spongy brake pedal indicates air remains in the system. Do not operate the vehicle until a firm pedal is achieved.
10. 10

    Reinstall wheel and perform final checks
    Reinstall the rear wheel, threading lug nuts by hand initially to prevent cross-threading. Lower the vehicle until the wheel just contacts the ground (to prevent rotation). Using a torque wrench and 19mm socket, tighten the lug nuts to the manufacturer's specification (typically 110-120 Nm for the Levante) in a star pattern. Fully lower the vehicle and remove jack stands. Check the master cylinder fluid level one final time and adjust to MAX if needed. Clean any brake fluid residue from the caliper, wheel, and surrounding areas.

Reassembly

1. Ensure all brake line connections are tight and leak-free before operating vehicle.
2. Verify brake pedal is firm with at least 2-3 inches of travel before resistance is felt.
3. Double-check that all caliper bracket bolts are torqued to 100 Nm specification.
4. Confirm master cylinder reservoir is filled to MAX line with fresh DOT 4 Racing brake fluid.
5. Clean all brake fluid spills from painted surfaces immediately to prevent damage.

Verification

• Start the engine and pump the brake pedal several times. Pedal should feel firm and consistent. If ABS/brake warning lights illuminate, address immediately before driving.
• With the engine running, press the brake pedal firmly and hold for 30 seconds. Pedal should not sink or feel spongy. If pedal sinks, air remains in the system—rebleed.
• Inspect the new caliper and all brake line connections for any signs of fluid leakage. Pay special attention to the banjo bolt connection.
• Perform a low-speed brake test in a safe area (parking lot or quiet street). At 5-10 mph, apply brakes firmly. Vehicle should stop straight without pulling to either side. Brakes should engage smoothly without noise or pulsation.
• After initial test drive, recheck all caliper bolts, brake line connections, and master cylinder fluid level. Test brakes at progressively higher speeds only after confirming proper function at low speeds.
• If any unusual brake behavior is observed (pulling, noise, soft pedal, warning lights), do not continue driving. Investigate and resolve the issue or seek professional service immediately.

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