Clutch Kit

Replace the dual-clutch assembly on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, requiring transmission removal and specialized dual-clutch service tools.

Warnings

Tools required

Parts

• Dual-clutch kit (includes both clutch discs and pressure plates) × 1 — Use OEM Maserati specification
• Release bearing (throw-out bearing) × 1 — Use OEM specification
• Flywheel bolts (if reusing flywheel) × 8 — One-time-use fasteners
• Transmission-to-engine mounting bolts × 6 — One-time-use fasteners
• Propshaft center bearing bolts × 4 — Use OEM specification
• Transmission mount hardware × 1 — One-time-use fasteners as needed

Fluids

• ZF Lifeguard 8 Automatic Transmission Fluid — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks at front wheels.
2. Disconnect negative battery cable and wait 10 minutes for airbag system capacitor discharge.
3. Raise vehicle on lift to working height and verify secure engagement on lift points.
4. Remove engine undertray and transmission heat shields.
5. Drain transmission fluid into appropriate container (note: fluid may be hot if vehicle recently operated).
6. Remove exhaust system from catalytic converters rearward to allow transmission clearance.
7. Disconnect propshaft at rear differential and transmission output flanges; support and remove propshaft.
8. Install engine support fixture across engine bay or attach hoist to engine lifting points to support engine weight.

Procedure

1. 1

   Disconnect electrical and mechanical connections
   Disconnect all electrical connectors from transmission including vehicle speed sensors, shift actuator connectors, and temperature sensors. Label each connector for reinstallation. Disconnect transmission cooler lines at transmission (have container ready for residual fluid). Remove shifter cable bracket and disconnect cable from transmission selector shaft.
2. 2

   Remove transmission crossmember and mounts
   Support transmission securely with transmission jack positioned at transmission pan with appropriate adapter. Remove rear transmission crossmember bolts (typically 4 bolts). Lower transmission jack slightly to relieve tension on transmission mounts. Remove transmission mount-to-transmission bolts on both sides.
3. 3

   Remove starter motor
   Disconnect starter motor electrical connections (main power cable and signal wire). Remove starter mounting bolts (typically 3 bolts) and carefully extract starter motor from bellhousing. Set aside in safe location.
4. 4

   Remove bellhousing-to-engine bolts
   Locate and remove all transmission-to-engine bellhousing bolts. There are typically 6-8 bolts of varying lengths around the bellhousing perimeter. Note bolt locations as lengths differ. Remove upper bellhousing bolts first, then lower bolts. Inspect for any remaining ground straps or brackets before attempting separation.
5. 5

   Separate and remove transmission
   Carefully slide transmission rearward on transmission jack, ensuring input shaft clears clutch splines. Maintain transmission level to prevent binding. Once input shaft is clear of clutch assembly, lower transmission jack and maneuver transmission out from under vehicle. Use caution not to allow transmission weight to hang on input shaft during removal.
   ⚠️Do not allow transmission weight to hang on clutch disc or input shaft during removal. This can damage clutch splines and alignment.
6. 6

   Remove dual-clutch assembly
   Mark pressure plate position relative to flywheel for reference (if reusing pressure plate, though not recommended). Progressively loosen pressure plate mounting bolts in star pattern, 1-2 turns at a time to prevent warping. Remove all bolts and carefully remove pressure plate and clutch disc assembly. Note orientation of clutch discs for proper installation. Inspect flywheel surface for heat damage, cracks, or scoring.
7. 7

   Inspect and prepare flywheel
   Clean flywheel surface thoroughly with brake cleaner and lint-free cloth. Inspect for heat spots (blue discoloration), cracks, hard spots, or scoring deeper than 0.5mm. Use dial indicator to check flywheel runout at friction surface (maximum typically 0.1mm). If flywheel requires resurfacing or replacement, remove flywheel bolts in star pattern and replace with new bolts during reinstallation. If flywheel is acceptable, proceed to clutch installation.
   ⚠Flywheel bolts are typically one-time-use torque-to-yield fasteners. Always use new bolts if flywheel is removed.
8. 8

   Install new release bearing
   Remove old release bearing from transmission input shaft bearing retainer. Clean bearing contact surfaces on transmission front cover. Install new release bearing onto input shaft guide tube, ensuring it moves freely and engages properly with release fork or hydraulic actuator. Apply small amount of high-temperature grease to bearing contact points only as specified in clutch kit instructions.
9. 9

   Install new clutch assembly
   Ensure flywheel surface is completely clean and dry. Position new clutch disc on flywheel with correct orientation (marked side typically faces pressure plate, or 'Getriebe/Transmission' side faces transmission). Insert clutch alignment tool through clutch disc hub into pilot bearing to center disc. Position new pressure plate over clutch disc, aligning dowel pins or reference marks. Install pressure plate bolts hand-tight in star pattern.
10. 10

    Torque pressure plate bolts
    Progressively torque pressure plate bolts in star pattern through multiple passes. First pass: torque to 50% of final specification. Second pass: torque to 100% of final specification (consult clutch kit instructions or service manual for exact values, typically 25-35 Nm). Final pass: verify all bolts are at proper torque. Do not remove alignment tool until transmission installation begins.
    ℹ️Without manufacturer torque specifications in database, consult clutch kit instructions or Maserati service manual for exact pressure plate bolt torque values.
11. 11

    Prepare transmission for installation
    Apply thin layer of high-temperature grease to transmission input shaft splines (do not over-grease as excess can contaminate clutch). Verify release bearing is properly seated and moves freely. Clean bellhousing mating surface on transmission. Position transmission on transmission jack and raise to approximate installation height.
12. 12

    Install transmission to engine
    Carefully align transmission with engine, ensuring input shaft aligns with clutch alignment tool. Slowly slide transmission forward, keeping it level. Input shaft should slide smoothly through clutch disc splines. If resistance is encountered, do not force; lower slightly and realign. Once bellhousing is approximately 10mm from engine block, verify alignment is correct. Continue pushing transmission forward until bellhousing contacts engine block. Remove clutch alignment tool once input shaft is partially engaged.
    ⚠Never use bellhousing bolts to draw transmission to engine. Transmission must slide into place freely or misalignment exists.
13. 13

    Install bellhousing bolts and starter
    Install all bellhousing-to-engine bolts in correct locations (refer to notes from removal). Start all bolts by hand before tightening. Torque bellhousing bolts in cross pattern per service manual specifications (typically 45-55 Nm for M10 bolts, 60-75 Nm for M12 bolts). Reinstall starter motor, torque mounting bolts, and reconnect electrical connections.
14. 14

    Reinstall transmission mounts and crossmember
    Raise transmission slightly with transmission jack to align mounting points. Install transmission mount brackets and bolts hand-tight. Install rear crossmember and bolts hand-tight. Verify all mounts are properly aligned before final tightening. Torque mount bolts and crossmember bolts per service manual specifications. Remove engine support fixture.
15. 15

    Reconnect components and refill transmission
    Reconnect transmission cooler lines with new sealing washers if equipped. Reconnect all electrical connectors using labels from removal. Reconnect shifter cable and adjust per service manual procedure. Install propshaft, aligning reference marks; torque fasteners to specification. Reinstall exhaust system with new gaskets as needed. Refill transmission with ZF Lifeguard 8 fluid through fill port. Use diagnostic scan tool to monitor fluid temperature and achieve proper fill level at 35-45°C. Install transmission heat shields and engine undertray.

Reassembly

1. Verify all electrical connectors are fully seated and locked.
2. Double-check all fasteners are torqued to specification, particularly bellhousing and flywheel bolts.
3. Ensure propshaft is properly aligned and all fasteners are secure.
4. Verify transmission fluid is at correct level with fluid at proper temperature using scan tool.
5. Reconnect negative battery cable.

Verification

• Start engine and verify no abnormal noises from bellhousing area. Clutch should engage smoothly without chatter.
• Use Maserati diagnostic software to perform clutch adaptation procedure. This is mandatory after clutch replacement.
• Perform transmission function test in all gear ranges while stationary (parking brake applied).
• Road test vehicle, verifying smooth engagement in all gears, no slipping under acceleration, and proper shift quality.
• Check for fluid leaks at transmission cooler lines, pan gasket, and bellhousing area after test drive.
• Verify no warning lights on instrument cluster and scan for diagnostic trouble codes.
• Re-check transmission fluid level after vehicle reaches operating temperature and perform final adjustment if necessary.

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