drivetrain

Differential Cover Gasket

for 2017 Maserati Levante 3.0L V6 Twin Turbo · AWD

Editorial review:Chris Hackleman — Master Technician · 20+ years · Jeff Moore — Master Lexus & Toyota Mechanic · 20+ years

Difficulty

Moderate

Time

2.2 h

Tools

Steps

✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman & Jeff Moore — 20+ years each). Always follow the vehicle's factory service information and torque specs.

Replace the rear differential cover gasket to address leaks, including draining and refilling the differential with fresh gear oil.

Warnings

⚠Used gear oil can be hot if vehicle was recently driven. Allow differential to cool for at least 30 minutes.

⚠Gear oil has a strong odor and can stain. Work in well-ventilated area and protect surrounding surfaces.

ℹ️Do not reuse old gasket material. Always install a new gasket to prevent leaks.

ℹ️Differential fill plug must be removed BEFORE drain plug to ensure it's not seized. If fill plug cannot be removed, do not drain.

Tools required

Socket set (metric)Essential

Torque wrench (10-100 Nm range)Essential

Floor jack and jack standsEssential

Drain pan (3+ quart capacity)Essential

Gasket scraper (plastic or composite)Essential

Brake cleaner or degreaserEssential

Lint-free shop ragsEssential

Fluid pump or squeeze bottle

Wire brush

RTV silicone sealant (if required by gasket type)

Parts

Rear differential cover gasket × 1 — Use OEM specification
Differential cover bolt sealing washers (if equipped) × 1 — Check OEM parts diagram

Fluids

75W-140 Synthetic Gear Oil — 2 qt

Preparation

Park vehicle on level surface and engage parking brake
Allow differential to cool if vehicle was recently driven
Raise rear of vehicle and support securely on jack stands at manufacturer-specified lift points
Clean exterior of differential cover and surrounding area to prevent contamination
Position drain pan beneath differential

Procedure

1
Locate and remove fill plug
Locate the differential fill plug on the front or side of the differential housing (not on the cover). Use appropriate socket to carefully remove the fill plug. This must be done BEFORE draining to ensure you can refill the differential after service.
2
Remove differential cover bolts
Starting from the bottom bolts and working upward, gradually loosen all differential cover bolts in a criss-cross pattern. Leave the top two bolts partially threaded to prevent cover from falling when seal breaks.
Torque spec
Differential Cover Bolts35 Nm (26 lb-ft)
3
Drain differential fluid
Position drain pan directly under cover. Remove the top two bolts and carefully pry the cover loose at the bottom edge to allow fluid to drain. Once majority of fluid has drained, remove cover completely. Expect approximately 2 quarts of gear oil to drain.
4
Remove old gasket material
Use plastic gasket scraper to carefully remove all old gasket material from both the differential housing mating surface and the cover. Be extremely careful not to gouge or scratch the aluminum surfaces. Remove any residual material with brake cleaner and lint-free rags. Inspect mating surfaces for damage or warping.
5
Clean cover and inspect internal components
Thoroughly clean the inside of the differential cover, removing all old fluid and debris. Inspect the magnetic drain plug (if equipped) and remove any metal particles. Visually inspect differential gears and bearings through the opening for obvious damage or excessive wear. Check for large metal chunks that would indicate internal damage.
6
Install new gasket
Position new gasket on differential cover, ensuring all bolt holes align properly. If gasket requires RTV sealant per manufacturer specifications, apply a thin, continuous bead to one surface only. Some OEM gaskets are dry-install type and require no sealant. Verify correct gasket orientation before installation.
7
Reinstall differential cover
Carefully position cover with gasket onto differential housing, ensuring gasket remains properly aligned. Start all bolts by hand to prevent cross-threading. Once all bolts are hand-tight, torque bolts in a criss-cross pattern starting from the center and working outward to ensure even gasket compression.
Torque spec
Differential Cover Bolts35 Nm (26 lb-ft)
8
Refill differential with gear oil
Using fluid pump or squeeze bottle, add 75W-140 synthetic gear oil through the fill hole until oil reaches the bottom of the fill plug opening (oil should just start to drip out). This typically requires approximately 2 quarts. Allow a few minutes for oil to settle and top off if needed.
9
Reinstall fill plug
Clean fill plug threads and inspect O-ring or sealing washer. Replace sealing washer if equipped. Reinstall fill plug and tighten to specification. Wipe away any excess oil from differential housing.
10
Clean work area and lower vehicle
Wipe down entire differential housing to remove any spilled gear oil. Properly dispose of used gear oil at recycling facility. Remove jack stands and carefully lower vehicle to ground. Double-check that all tools have been removed from under vehicle.

Reassembly

Ensure all differential cover bolts are torqued to 35 Nm (26 lb-ft) in proper sequence
Verify fill plug is properly installed and not leaking
Clean any gear oil residue from exterior surfaces to make leak detection easier

Verification

With vehicle on level ground, check fill plug area for leaks
Inspect differential cover gasket seam for any signs of oil seepage
Drive vehicle for 10-15 minutes, then recheck for leaks while differential is at operating temperature
After first drive, verify gear oil level through fill plug opening and top off if necessary
Monitor for leaks over the next few days of normal driving

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