Clutch Disc

Remove and replace the clutch disc on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD by dropping the transmission and accessing the clutch assembly from underneath.

Warnings

Tools required

Parts

• Clutch disc × 1 — Use OEM specification
• Pressure plate (if replacing complete clutch kit) × 1 — Use OEM specification
• Release bearing × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Pilot bearing × 1 — Use OEM specification
• Clutch slave cylinder (inspect and replace if leaking) × 1 — Use OEM specification
• Transmission mounting bolts (reuse unless damaged) × 1 — Use OEM specification
• Driveshaft flange bolts (recommended replacement) × 6 — Use OEM specification

Fluids

• ZF Lifeguard 8 — 10 qt

Preparation

1. Ensure vehicle is on a lift or securely supported on jack stands with adequate clearance for transmission removal
2. Disconnect negative battery cable and wait 10 minutes for systems to discharge
3. Remove engine undertray and transmission undertray panels
4. Mark driveshaft and differential flange orientation for proper reinstallation alignment
5. Place transmission jack under transmission and secure with safety straps
6. Install engine support bar across engine bay to support engine weight during transmission removal
7. Drain transmission fluid into appropriate container by removing drain plug
8. Have all replacement parts, tools, and fluids ready before starting disassembly

Procedure

1. 1

   Disconnect exhaust system
   Disconnect exhaust system at the connection point behind the catalytic converters. Remove exhaust hangers and lower exhaust system enough to provide clearance for transmission removal. Support exhaust with stands to prevent damage to hangers or flex joints.
2. 2

   Remove driveshaft
   Mark alignment of driveshaft to rear differential flange with paint marker. Remove six driveshaft flange bolts at differential end using impact wrench or breaker bar. Slide driveshaft forward to separate from differential, then lower and remove from vehicle. Install transmission output shaft plug or plastic bag secured with zip tie to prevent fluid leakage and contamination.
3. 3

   Disconnect shift linkage and electrical connections
   Disconnect shift linkage at transmission by removing retaining clips and pivot pins. Label and disconnect all electrical connectors including vehicle speed sensor, reverse light switch, and clutch position sensor. Disconnect clutch hydraulic line at transmission slave cylinder - be prepared for minor fluid spillage.
4. 4

   Remove starter motor
   Disconnect electrical connections from starter motor. Remove starter mounting bolts and carefully extract starter from bellhousing. This provides access to lower bellhousing bolts and reduces weight during transmission removal.
5. 5

   Support and disconnect transmission mounts
   Ensure transmission jack is securely positioned under transmission pan with safety straps. Remove transmission crossmember mounting bolts. Lower transmission slightly (approximately 2 inches) to access upper bellhousing bolts while monitoring clearance around engine and chassis components.
6. 6

   Remove bellhousing bolts
   Remove all bellhousing-to-engine mounting bolts. There are typically 6-8 bolts of varying lengths around the perimeter. Note location and length of each bolt for proper reinstallation. Ensure transmission is fully supported on jack before removing final bolts.
7. 7

   Separate transmission from engine
   Carefully slide transmission straight back away from engine, ensuring input shaft clears clutch disc splines. Transmission must move horizontally to avoid damaging clutch disc or input shaft. Lower transmission on jack once clear of engine and remove from under vehicle. Use caution as transmission weighs approximately 200 lbs.
8. 8

   Inspect and mark clutch assembly
   With transmission removed, inspect clutch pressure plate, disc, and flywheel for wear, hot spots, or damage. Mark pressure plate orientation to flywheel with paint marker if reusing. Check flywheel surface for glazing, cracks, or heat damage - resurface or replace if necessary. Inspect pilot bearing in crankshaft for wear or roughness.
9. 9

   Remove pressure plate and clutch disc
   Loosen pressure plate mounting bolts gradually in a cross-pattern, turning each bolt 1-2 turns at a time to prevent warping. Once all bolts are loose, remove bolts completely and carefully remove pressure plate. Catch clutch disc as pressure plate is removed - note which side faces flywheel for proper new disc orientation.
10. 10

    Clean and inspect mating surfaces
    Clean flywheel surface with brake cleaner and wire brush, removing all oil, grease, and debris. Inspect flywheel for cracks, hot spots, or glazing - surface should be smooth with no discoloration. Check crankshaft pilot bearing for smooth rotation and replace if worn. Clean pressure plate mounting surface on flywheel.
11. 11

    Install new pilot bearing
    If replacing pilot bearing, carefully drive or press new bearing into crankshaft pilot bore. Ensure bearing is seated to proper depth and oriented correctly. Pack bearing lightly with high-temperature grease suitable for clutch applications.
12. 12

    Install new clutch disc and pressure plate
    Position new clutch disc on flywheel with correct orientation - longer hub side typically faces transmission, but verify with manufacturer markings. Insert clutch alignment tool through disc hub into pilot bearing to center disc. Position new or resurfaced pressure plate over disc, aligning previous marks if reusing. Install pressure plate bolts hand-tight, then torque in cross-pattern gradually to manufacturer specification (typically 20-25 Nm final torque). Remove alignment tool only after all bolts are torqued.
13. 13

    Install new release bearing
    Clean transmission input shaft bearing retainer with brake cleaner. Install new release bearing onto input shaft bearing retainer, ensuring proper engagement with clutch fork or hydraulic actuator. Apply small amount of high-temperature grease to input shaft splines and bearing contact points. Verify bearing moves smoothly on retainer.
14. 14

    Reinstall transmission
    Apply thin coat of high-temperature grease to transmission input shaft splines. Position transmission on jack and raise into position, ensuring proper height and angle alignment with engine. Carefully guide input shaft through release bearing and into clutch disc splines, using clutch alignment marks as reference. Transmission should slide forward smoothly - never force it. If binding occurs, lower and realign. Once transmission is fully seated against engine block with no gaps, install bellhousing bolts in original locations and torque to specification (typically 60-80 Nm).
15. 15

    Reconnect all components
    Reinstall transmission crossmember and torque mounting bolts to specification. Reinstall starter motor and electrical connections. Reconnect clutch hydraulic line and bleed system if required. Reconnect all electrical connectors and shift linkage. Align and install driveshaft to differential, matching original alignment marks, and install new flange bolts with thread locker. Torque driveshaft bolts in star pattern. Reconnect exhaust system and hangers. Reinstall transmission and engine undertrays.

Reassembly

1. Refill transmission with 10 quarts of ZF Lifeguard 8 fluid to proper level
2. Bleed clutch hydraulic system if hydraulic line was disconnected
3. Reconnect battery negative cable
4. Verify all electrical connections are secure and properly seated
5. Check that no tools or parts were left in engine bay or under vehicle

Verification

• Start engine and verify no abnormal noises from clutch or transmission area
• With engine running and clutch pedal depressed, verify smooth engagement into first and reverse gears with no grinding
• Test drive vehicle through all gears, verifying smooth clutch engagement and disengagement
• Check clutch pedal feel and operation - pedal should have proper resistance and return fully
• Verify no fluid leaks from transmission, clutch hydraulic system, or driveshaft connections
• Confirm proper clutch bite point is within normal range (typically mid-pedal travel)
• Test hill starts and verify clutch holds without slipping under load

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