Flywheel Resurface

This procedure covers the removal, inspection, and resurfacing of the flywheel on a 2017 Maserati Levante with the 3.0L V6 Twin Turbo engine, requiring transmission removal and clutch system disassembly.

Warnings

Tools required

Parts

• Flywheel (if resurfacing exceeds limits) × 1 — Use OEM specification
• Clutch disc (inspect and replace if worn) × 1 — Use OEM specification
• Pressure plate (inspect and replace if worn) × 1 — Use OEM specification
• Release bearing × 1 — Use OEM specification
• Pilot bearing × 1 — Use OEM specification
• Flywheel bolts × 8 — Use OEM specification - often single-use
• Pressure plate bolts × 6 — Use OEM specification
• Transmission mount fasteners × 1 — Use OEM specification
• Driveshaft hardware × 1 — Use OEM specification as needed

Fluids

• ZF Lifeguard 8 — 10 qt

Preparation

1. Verify flywheel resurfacing is available at local machine shop and confirm turnaround time before beginning disassembly.
2. Disconnect negative battery cable and wait 10 minutes for system capacitor discharge.
3. Raise vehicle on lift or securely support on jack stands at all four corners at manufacturer-specified lift points.
4. Remove engine undertray and transmission skid plate if equipped.
5. Install engine support bar across engine bay to support engine weight during transmission removal.
6. Mark driveshaft-to-differential flange orientation for proper reinstallation alignment.

Procedure

1. 1

   Drain transmission fluid
   Place drain pan under transmission. Remove transmission drain plug and allow fluid to drain completely. Remove transmission fill plug to verify complete drainage. Keep fluid clean if reusing, though replacement is recommended during this service.
2. 2

   Disconnect driveshaft
   Remove the four bolts securing driveshaft to rear differential flange. Support driveshaft and remove center support bearing bolts. Carefully lower driveshaft and slide forward to disconnect from transmission output shaft. Cap transmission output to prevent fluid loss and contamination.
3. 3

   Disconnect transmission electrical and mechanical connections
   Disconnect transmission wiring harness connectors including shift solenoid pack, speed sensors, and temperature sensor. Remove transmission vent tube. Disconnect shift linkage by removing retaining clip and sliding cable end off ball stud. Disconnect any ground straps from transmission case.
4. 4

   Remove starter motor
   Disconnect starter motor electrical connections including main power cable and signal wire. Remove the three starter mounting bolts and extract starter motor from bellhousing. Note starter shim arrangement if present for proper reinstallation.
5. 5

   Support and remove transmission crossmember
   Position transmission jack under transmission pan with wood block to distribute load. Raise jack slightly to take load off crossmember. Remove transmission mount-to-crossmember fasteners, then remove crossmember-to-frame bolts. Lower crossmember away from vehicle.
6. 6

   Remove bellhousing and transmission
   Remove all bellhousing-to-engine block bolts, working around perimeter. There are typically 8-10 bolts of varying lengths; note locations for reinstallation. Carefully slide transmission straight back on jack to disengage input shaft from clutch disc and pilot bearing. Lower transmission from vehicle with assistant guiding.
   ⚠️Transmission weight is approximately 200 lbs. Ensure transmission jack is secure and have assistant stabilize during removal.
7. 7

   Remove clutch pressure plate and disc
   Install flywheel holding tool to prevent rotation. Mark pressure plate-to-flywheel orientation with paint pen. Loosen pressure plate bolts in star pattern, 1-2 turns at a time to gradually release spring tension. Remove all bolts and carefully remove pressure plate and clutch disc as assembly. Inspect clutch disc for oil contamination, glazing, or wear below minimum thickness.
8. 8

   Remove flywheel
   With flywheel holding tool engaged, remove flywheel mounting bolts in star pattern. There are typically 8 bolts. Remove flywheel from crankshaft flange. Inspect crankshaft flange surface for damage, grooves, or runout. Clean crankshaft flange and flywheel bolt holes with brake cleaner and compressed air.
9. 9

   Inspect and measure flywheel
   Clean flywheel friction surface thoroughly. Inspect for cracks, heat checking, hot spots, or scoring. Measure flywheel thickness at multiple points with micrometer. Check flywheel face runout with dial indicator if available. Maximum runout is typically 0.006 inches. Minimum thickness and maximum resurfacing depth typically allow 0.040 inches material removal total over flywheel life.
10. 10

    Resurface flywheel at machine shop
    Transport flywheel to machine shop for resurfacing. Specify minimum material removal to achieve smooth surface. Request final measurement verification. Typical resurface removes 0.010-0.020 inches. If flywheel is at or beyond minimum thickness, replace with new unit rather than resurface.
11. 11

    Replace pilot bearing and inspect rear main seal
    Remove pilot bearing from crankshaft center bore using slide hammer with internal puller or bearing puller. Install new pilot bearing using appropriate driver to seat flush with crankshaft end. Inspect rear main seal for leakage; replace if any oil seepage is evident as this is optimal access point.
12. 12

    Install resurfaced flywheel
    Clean crankshaft flange and flywheel mounting surface with brake cleaner. Apply small amount of threadlocker to flywheel bolt threads if specified. Position flywheel on crankshaft flange, aligning dowel pins. Install new flywheel bolts hand-tight. Using flywheel holding tool, torque bolts in star pattern to specification in three progressive stages: 30%, 60%, then 100% of final torque. Verify no torque spec is listed in database; consult factory service manual for exact specification (typically 55-75 ft-lbs for this application).
13. 13

    Install clutch disc and pressure plate
    Install new release bearing on transmission input shaft bearing retainer if not already installed. Clean pressure plate and flywheel surfaces with brake cleaner. Position clutch disc on flywheel with longer hub side facing transmission (typically marked 'Getriebe Seite' or 'Transmission Side'). Insert clutch alignment tool through disc hub into pilot bearing. Position pressure plate over clutch disc, aligning previous marks or dowel pins. Install pressure plate bolts hand-tight. Torque bolts in star pattern gradually to specification (consult factory manual, typically 18-22 ft-lbs). Remove alignment tool only after all bolts are torqued.
14. 14

    Reinstall transmission
    Apply thin coat of high-temperature grease to transmission input shaft splines (do not over-grease). Verify clutch disc is centered with alignment tool still in place or verify by visual inspection. Position transmission on jack and raise into position. Carefully align input shaft with clutch disc hub and pilot bearing while guiding transmission into bellhousing. Slide transmission forward until flush with engine block; do not force. Install all bellhousing bolts and torque in star pattern to specification (consult factory manual, typically 40-50 ft-lbs).
15. 15

    Reinstall remaining components
    Install transmission crossmember and torque fasteners to specification. Remove transmission jack and engine support bar. Reinstall starter motor with any shims in original positions. Reconnect all transmission electrical connectors, shift linkage, and ground straps. Reinstall driveshaft, aligning marks made during disassembly. Torque all driveshaft fasteners to specification. Reinstall transmission skid plate and engine undertray. Refill transmission with 10 quarts ZF Lifeguard 8 fluid through fill port using fluid pump. Reconnect battery negative cable.

Reassembly

1. Use new flywheel bolts if specified as torque-to-yield by manufacturer.
2. Replace clutch disc, pressure plate, release bearing, and pilot bearing as preventive maintenance given labor overlap.
3. Ensure clutch alignment tool remains in place until pressure plate is fully torqued.
4. Verify transmission is fully seated to bellhousing before installing bolts; gap indicates misalignment.
5. Use only ZF Lifeguard 8 transmission fluid; do not substitute generic ATF.

Verification

• Start engine and verify no abnormal noises from bellhousing area.
• With engine at operating temperature, verify smooth clutch engagement and disengagement through all gears.
• Test drive vehicle and verify no clutch slippage under load, no chatter during engagement, and smooth shifts.
• Check for transmission fluid leaks at all connection points after test drive.
• Verify no driveline vibration indicating driveshaft misalignment.
• Re-verify transmission fluid level after test drive when fluid is at operating temperature.

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