Dual Mass Flywheel

Replace the dual mass flywheel on a 2017 Maserati Levante 3.0L V6 Twin Turbo, requiring transmission removal and clutch system disassembly.

Warnings

Tools required

Parts

• Dual mass flywheel × 1 — Use OEM specification
• Clutch disc × 1 — Replace with flywheel
• Pressure plate × 1 — Replace with flywheel
• Release bearing × 1 — Use OEM specification
• Flywheel bolts × 6 — TTY bolts - use new
• Transmission drain plug washer × 1 — Copper crush washer
• Transmission pan gasket or RTV sealant × 1 — Check specific transmission variant
• Rear differential drain plug washer × 1 — Use new washer

Fluids

• ZF Lifeguard 8 — 10 qt
• 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and isolate to prevent accidental electrical contact
3. Raise vehicle on lift or jack stands to provide adequate working clearance underneath
4. Remove engine undertray and transmission protective covers
5. Allow transmission and differential to cool completely if recently operated
6. Mark driveshaft to transmission and differential flanges for proper reinstallation alignment
7. Have all replacement parts, fluids, and tools readily accessible before beginning disassembly

Procedure

1. 1

   Drain transmission and differential fluids
   Position drain pan under transmission. Remove transmission drain plug and allow fluid to drain completely. Reinstall drain plug with new crush washer. Move drain pan to rear differential, remove drain plug, drain fluid, and reinstall with new washer. Remove transmission pan bolts in reverse sequence and lower pan to access internal filter if applicable.
2. 2

   Remove driveshaft and exhaust components
   Remove driveshaft center support bearing mounting bolts. Mark driveshaft-to-transmission and driveshaft-to-differential flange positions with paint marker. Remove driveshaft mounting bolts at both flanges and carefully lower driveshaft from vehicle. Disconnect exhaust hangers and remove exhaust system from catalytic converters back to provide transmission clearance.
3. 3

   Disconnect transmission electrical and mechanical connections
   Disconnect transmission wiring harness connectors including range sensor, solenoid pack, and speed sensors. Remove transmission cooler lines and cap openings to prevent contamination. Disconnect shift linkage at transmission. Remove transmission crossmember mounting bolts and slowly lower crossmember while supporting transmission with transmission jack.
4. 4

   Support engine and remove transmission mounting
   Install engine support bar across engine bay or attach engine hoist to secure lifting points. Support engine weight to prevent damage to motor mounts. Position transmission jack under transmission with secure load distribution. Remove all transmission bellhousing bolts, noting different bolt lengths and positions for reassembly.
5. 5

   Separate and lower transmission
   Carefully pry transmission away from engine block using pry points (do not pry on mating surfaces). Slide transmission straight back on guide pins until input shaft clears clutch splines. Slowly lower transmission on jack, ensuring all electrical connections and brackets are clear. Tilt transmission nose downward as needed to clear chassis during removal. Have assistant guide transmission clear of vehicle.
   ⚠️Transmission must remain level and secure on jack during removal. Ensure jack saddle is properly positioned and strapped before lowering.
6. 6

   Remove clutch pressure plate and disc
   Mark pressure plate orientation to flywheel for reference. Install clutch alignment tool through clutch disc to support it. Gradually loosen pressure plate bolts in star pattern, one turn at a time, to release spring tension evenly. Remove all pressure plate bolts, then remove pressure plate and clutch disc as assembly. Inspect release bearing on transmission input shaft; replace if worn.
7. 7

   Remove dual mass flywheel
   Install flywheel holding tool or lock ring gear with appropriate tool to prevent crankshaft rotation. Remove all flywheel mounting bolts in star pattern. Note location of any dowel pins. Carefully remove flywheel from crankshaft, supporting weight to prevent dropping. Inspect crankshaft flange for damage, scoring, or oil leaks from rear main seal.
   ⚠Dual mass flywheel weighs approximately 35-40 lbs. Use proper lifting technique and support flywheel completely during removal.
8. 8

   Inspect and prepare mating surfaces
   Clean crankshaft flange thoroughly with brake cleaner and lint-free cloth. Inspect rear main seal for leaks; replace if any seepage is visible. Check crankshaft flange runout with dial indicator if available (maximum 0.1mm runout). Ensure all dowel pins are present and properly seated. Verify pilot bearing condition in crankshaft; replace if rough or dry.
9. 9

   Install new dual mass flywheel
   Verify new flywheel matches original part and rotates smoothly without excessive play (small amount of movement is normal for dual mass design). Position flywheel on crankshaft flange, aligning dowel pins. Install new flywheel bolts hand-tight in star pattern. Secure flywheel with holding tool. Torque flywheel bolts in star pattern to specification in three progressive stages: 30 Nm, 60 Nm, then final 95 Nm.
   ⚠Must use new flywheel bolts. Old TTY bolts have stretched threads and cannot achieve proper clamping force.
10. 10

    Install new clutch disc and pressure plate
    Clean flywheel friction surface with brake cleaner (do not use oil-based products). Position new clutch disc on flywheel with correct orientation (marked side typically faces pressure plate, verify in parts documentation). Insert clutch alignment tool through disc and into pilot bearing. Position new pressure plate over clutch disc, aligning with previous marks or dowels. Install pressure plate bolts hand-tight.
11. 11

    Torque pressure plate and verify alignment
    Gradually tighten pressure plate bolts in star pattern, working in multiple stages to seat pressure plate evenly against flywheel. Final torque specification typically 25-30 Nm (verify with clutch kit specifications). Leave clutch alignment tool installed. Install new release bearing on transmission input shaft, ensuring proper engagement with fork or hydraulic actuator. Apply small amount of high-temperature grease to input shaft splines.
12. 12

    Reinstall transmission
    Apply thin layer of high-temperature grease to transmission input shaft splines (avoid excess that could contaminate clutch). Position transmission on jack and raise into position. Ensure clutch alignment tool remains centered. Guide transmission input shaft into clutch splines using alignment tool as guide. Slide transmission forward onto alignment pins until bellhousing contacts engine block. Remove clutch alignment tool once input shaft is partially engaged.
    ⚠Do not use transmission bolts to draw transmission to engine. Transmission must slide freely onto alignment pins. Forcing may damage clutch disc or input shaft.
13. 13

    Secure transmission and install crossmember
    Install all bellhousing bolts hand-tight, noting correct bolt lengths for each position. Torque all bellhousing bolts to specification. Raise transmission crossmember into position and install mounting bolts. Reconnect shift linkage at transmission. Reconnect all transmission electrical connectors ensuring positive engagement. Install transmission cooler lines with new O-rings if equipped.
14. 14

    Reinstall driveshaft and exhaust system
    Position driveshaft and align marks made during disassembly at both transmission and differential flanges. Install driveshaft flange bolts and torque to specification. Install center support bearing mounting bolts. Reinstall exhaust system, connecting at catalytic converters and securing all hangers. Verify adequate clearance between driveshaft and exhaust components throughout suspension travel.
15. 15

    Refill fluids and perform final checks
    Refill rear differential with 2.0 quarts of 75W-140 synthetic gear oil through fill plug opening. Install fill plug to specification. Refill transmission with ZF Lifeguard 8 fluid through fill tube. Initial fill approximately 5-6 quarts, then follow ZF procedure: start engine, run through all gear ranges with brake applied, check fluid temperature with scan tool, add fluid to proper level at 35-45°C operating temperature. Install transmission pan with new gasket/sealant and torque bolts in criss-cross pattern. Reconnect battery. Install all covers and undertray components.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Check that all drain and fill plugs are torqued to specification with new washers installed
3. Confirm driveshaft alignment marks match original positions
4. Ensure transmission fluid level is correct at operating temperature per ZF procedure
5. Verify no tools or parts have been left in engine bay or under vehicle

Verification

• Start engine and verify no abnormal noises from bellhousing area
• Check for fluid leaks at transmission pan, drain plug, cooler lines, and differential
• Test clutch engagement point with vehicle stationary; should be smooth and consistent
• Perform test drive through all gears, verifying smooth shifts and proper clutch operation
• Listen for dual mass flywheel noise at idle; should be minimal (slight rattle at idle can be normal for DMF)
• Check for vibration at various RPM ranges; excessive vibration may indicate improper flywheel installation
• Recheck transmission fluid level after test drive at operating temperature
• Scan for any transmission fault codes using appropriate diagnostic equipment

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