Brake Pads and Rotors - Front

Replace front brake pads and rotors on a 2017 Maserati Levante 3.0L V6 Twin Turbo, including proper caliper service and torque specifications.

Warnings

Tools required

Parts

• Front brake pads (set of 4) × 1 — Use OEM specification
• Front brake rotors × 2 — Use OEM specification
• Brake pad wear sensors (if equipped) × 2 — Use OEM specification
• Thread locker (medium strength) × 1 — Loctite 243 or equivalent
• High-temperature silicone brake grease × 1 — Use synthetic formulation
• Anti-seize compound × 1 — Copper or ceramic based

Fluids

• DOT 4 Racing Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Chock rear wheels securely
3. Open hood and check brake fluid reservoir level - remove some fluid with turkey baster if near maximum (pistons will be compressed during procedure)
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Lift front of vehicle using proper jacking points and secure on jack stands rated for vehicle weight
6. Remove front wheels completely
7. Spray brake components with brake cleaner and allow to dry, avoiding breathing dust or spray mist
8. Inspect brake lines and hoses for damage, cracks, or leaks - replace if any issues found

Procedure

1. 1

   Remove caliper slide bolts and caliper
   Locate the caliper slide pin bolts on the rear of the caliper. These are typically hex/Allen head bolts. Use the appropriate hex key to remove both slide pin bolts. Once removed, carefully pivot the caliper upward and off the rotor. Support the caliper with a wire hanger or bungee cord attached to the suspension - never let it hang by the brake hose.
2. 2

   Remove old brake pads and inspect hardware
   Remove the brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips, shims, or springs. Disconnect the brake pad wear sensor connector if equipped (usually on inner pad). Inspect all pad hardware clips and springs for damage or excessive wear - replace if necessary. Clean the pad contact points on the bracket with a wire brush.
3. 3

   Remove caliper bracket
   Remove the two caliper bracket bolts that secure the bracket to the steering knuckle. These are large bolts requiring significant torque. Use a breaker bar if necessary. Once removed, take off the caliper bracket completely to access the rotor. Note any thread locker residue on bolt threads.
   Torque spec

   Bracket Bolts107 Nm (79 lb-ft)
4. 4

   Remove old rotor
   Remove the rotor retaining screw if present (may require impact driver if seized). If rotor is stuck due to corrosion, use penetrating oil and tap around the hat section with a rubber mallet - never strike the friction surface. Once free, remove the old rotor. Clean the hub face thoroughly with a wire brush to remove all rust and debris.
   ⚠Do not strike the rotor friction surface or edge as this can cause cracks or injury from sharp metal edges.
5. 5

   Inspect hub and install new rotor
   Inspect the wheel hub for damage, excessive runout, or bearing play. Apply a thin layer of anti-seize compound to the hub face (avoid getting any on rotor friction surfaces). Install the new rotor onto the hub, ensuring it sits flush. If equipped, reinstall rotor retaining screw finger-tight. Clean both sides of the new rotor with brake cleaner to remove any protective coating or oils.
   ⚠New rotors are coated with protective oil. Failure to clean thoroughly will cause brake contamination and reduced braking performance.
6. 6

   Reinstall caliper bracket
   Clean the caliper bracket bolt threads and holes with a wire brush. Apply medium-strength thread locker to the bracket bolt threads as specified. Position the caliper bracket onto the steering knuckle and install both bracket bolts. Torque the bracket bolts to specification in a cross pattern.
   Torque spec

   Bracket Bolts107 Nm (79 lb-ft)
7. 7

   Prepare caliper and compress pistons
   With the caliper supported off the vehicle, inspect the caliper pistons for damage, leaks, or corrosion. Check the piston boots for tears or deterioration. Using a C-clamp or brake caliper piston tool, slowly compress the caliper pistons fully into their bores. Monitor the brake fluid reservoir - do not allow it to overflow. If pistons do not compress smoothly or caliper shows signs of leakage, caliper rebuild or replacement is required.
   ⚠️If brake fluid overflows from reservoir during piston compression, it can damage paint and create a slipping hazard. Monitor fluid level continuously.
8. 8

   Install new brake pads
   Apply a thin layer of high-temperature silicone brake grease to the pad backing plate contact points on the caliper bracket (not to friction material). Install any anti-rattle clips and hardware in their original positions. Install the new brake pads into the caliper bracket with friction material facing the rotor. Reconnect the brake pad wear sensor to the inner pad if equipped, ensuring the wire is properly routed and secured.
9. 9

   Lubricate and reinstall caliper
   Remove the caliper slide pins from the caliper bracket. Clean the slide pins thoroughly with brake cleaner and inspect for wear or corrosion. Apply a generous coating of silicone brake grease to the slide pins. Reinstall the slide pins into their bores. Position the caliper over the brake pads and rotor. Install the caliper slide pin bolts and torque to specification.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Repeat for opposite side
    Repeat all previous steps for the opposite front brake assembly. Always replace brake pads and rotors in axle sets (both front wheels) to ensure balanced braking performance.
11. 11

    Reinstall wheels and perform initial checks
    Reinstall both front wheels onto the hubs. Install lug nuts hand-tight in a star pattern. Lower the vehicle until wheels just contact the ground but most weight is still on jack stands. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands. Torque lug nuts again in star pattern to final specification.
    ⚠Improper lug nut torque can cause wheel detachment or rotor warping. Use calibrated torque wrench and star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
12. 12

    Bed brakes and check brake fluid
    With engine running, pump the brake pedal several times until it becomes firm - this repositions the caliper pistons against the new pads. Check brake pedal firmness and travel. Check brake fluid reservoir level and top off with DOT 4 Racing Brake Fluid if necessary. Do not overfill. Perform initial brake bedding procedure: drive at moderate speed and apply brakes gently 20-30 times to transfer pad material to rotors. Avoid hard braking for first 200-300 miles.
    ⚠️New brakes have reduced stopping power until properly bedded. Allow extra stopping distance for first 200-300 miles.
    ⚠If brake pedal feels soft or spongy after pumping, air may be in the system. Professional brake bleeding is required before driving.

Reassembly

1. Ensure all caliper bolts are torqued to proper specifications with appropriate thread locker applied
2. Verify brake pad wear sensors are properly connected and wires are secured away from rotating components
3. Confirm brake fluid level is between MIN and MAX marks on reservoir
4. Double-check that all tools and parts have been removed from wheel wells
5. Verify wheel lug nuts are torqued to specification in star pattern

Verification

• With engine running, pump brake pedal - it should become firm within 2-3 pumps and hold steady pressure
• Brake pedal should not sink slowly when held under steady pressure
• Test drive in safe area at low speed (under 25 mph) - brakes should engage smoothly without pulling to one side
• No grinding, squealing, or rubbing noises should be present (light noise during initial bedding is normal)
• Check for brake fluid leaks around calipers and brake lines after test drive
• Verify no vibration or pulsation in brake pedal during braking
• After 50-100 miles, re-check wheel lug nut torque
• If any abnormalities are detected (soft pedal, pulling, noise, vibration), stop driving immediately and seek professional service

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