Flywheel

Complete flywheel replacement procedure for 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including transmission removal, clutch assembly access, and flywheel installation with proper torque specifications.

Warnings

Tools required

Parts

• Flywheel (dual-mass or single-mass as equipped) × 1 — Use OEM specification
• Clutch disc × 1 — Replace with flywheel
• Pressure plate assembly × 1 — Replace with flywheel
• Release bearing (throwout bearing) × 1 — Replace with flywheel
• Flywheel bolts × 8 — TTY bolts - replace every time
• Transmission drain plug crush washer × 1 — Use OEM specification
• Rear main seal × 1 — Recommended replacement
• Transmission input shaft seal × 1 — Inspect and replace if needed
• Transmission pan gasket or RTV sealant × 1 — If pan removal required

Fluids

• ZF Lifeguard 8 — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Disconnect negative battery terminal and wait 15 minutes for SRS system to discharge.
3. Raise vehicle on lift or jack stands to provide adequate working clearance underneath.
4. Remove engine undertray and transmission splash shields for access.
5. Place transmission drain pan under transmission and drain fluid through drain plug. Note: Some fluid will remain in torque converter.
6. Install engine support fixture across engine bay or attach engine hoist to lifting points to support engine weight during transmission removal.
7. Mark driveshaft-to-differential flange orientation for proper reinstallation alignment.

Procedure

1. 1

   Remove driveshaft and exhaust components
   Remove the four driveshaft mounting bolts at the rear differential flange. Mark orientation before removal. Support driveshaft and remove from transmission output. Remove exhaust system from catalytic converters rearward to provide clearance for transmission removal. Support exhaust components properly to avoid damage to hangers or oxygen sensors.
2. 2

   Disconnect transmission electrical connections and shifter linkage
   Disconnect all electrical connectors from transmission including range sensor, speed sensors, solenoid pack connector, and temperature sensor. Label all connectors for reassembly. Disconnect shift cable from transmission lever and remove cable bracket from transmission housing. Remove any ground straps attached to transmission bellhousing.
3. 3

   Remove transmission cooler lines and crossmember
   Disconnect transmission cooler lines at transmission fittings. Be prepared for additional fluid spillage. Cap all openings immediately to prevent contamination. Remove transmission crossmember mounting bolts and carefully lower crossmember away. Ensure transmission jack is positioned and secured under transmission before removing crossmember support.
   ⚠Transmission weight will shift when crossmember is removed. Ensure transmission jack is properly positioned and secured.
4. 4

   Remove starter motor and inspection covers
   Remove starter motor mounting bolts and disconnect electrical connections. Carefully remove starter and set aside. Remove lower bellhousing inspection covers and dust shields to access flywheel and clutch assembly. These covers are secured with multiple bolts around the perimeter.
5. 5

   Support and separate transmission from engine
   Verify transmission jack is secure and centered under transmission. Remove all bellhousing-to-engine block mounting bolts (typically 6-8 bolts of various lengths - note locations for reassembly). Carefully pry transmission away from engine using pry points on bellhousing. Transmission must move straight back to avoid damaging clutch disc or input shaft. Once input shaft clears clutch splines, lower transmission on jack and roll away from vehicle.
   ⚠️Transmission weighs approximately 190 lbs and will shift weight suddenly when it separates from engine. Maintain secure grip on transmission jack controls.
   ⚠Do not let transmission hang at an angle while input shaft is engaged with clutch disc as this will damage clutch splines.
6. 6

   Remove clutch pressure plate and disc
   Using clutch alignment tool or by hand, support clutch disc to prevent it from falling. Remove pressure plate mounting bolts in a criss-cross pattern, loosening each bolt 2-3 turns at a time to evenly release spring pressure. Once all bolts are removed, carefully remove pressure plate and clutch disc. Inspect release bearing and pilot bearing condition.
7. 7

   Lock crankshaft and remove flywheel bolts
   Install flywheel holding tool into ring gear or use locking pins in flywheel bolt holes to prevent crankshaft rotation. Using impact wrench or breaker bar, remove all flywheel mounting bolts. These are typically 8 bolts arranged in a circular pattern. Note: These are torque-to-yield bolts and must be replaced with new bolts during installation. Remove flywheel from crankshaft flange, noting any dowel pin locations.
   ⚠Flywheel is heavy (25-40 lbs depending on type) and may release suddenly when final bolt is removed. Maintain secure grip.
8. 8

   Inspect and clean crankshaft flange
   Thoroughly inspect crankshaft flange for cracks, wear, or damage. Check rear main seal for leakage - replace if any seepage is present as this is ideal access time. Clean crankshaft flange surface with brake cleaner and lint-free cloth. Ensure all bolt holes are clean and threads are undamaged. If dual-mass flywheel was removed, inspect for rattling, excessive play, or heat discoloration - replace if any defects found. Measure flywheel runout with dial indicator if resurfacing (single-mass only) - maximum runout typically 0.005 inch.
   ℹ️Dual-mass flywheels cannot be resurfaced and must be replaced if friction surface shows any wear, scoring, or heat damage beyond light discoloration.
9. 9

   Install new flywheel
   Align new flywheel onto crankshaft flange, ensuring any dowel pins are properly seated. Install NEW flywheel bolts (never reuse TTY bolts) and hand-tighten all bolts. Apply small amount of medium-strength thread locker to bolt threads if specified. Using flywheel holding tool to prevent rotation, tighten flywheel bolts in star/cross pattern to proper torque specification. Make multiple passes: first pass to 50% torque, second pass to 100% torque (95 Nm / 70 lb-ft). Verify all bolts are properly torqued.
   ⚠Must use star pattern tightening sequence to ensure even clamping force and prevent flywheel distortion. Uneven tightening can cause vibration and premature failure.
10. 10

    Install new clutch assembly
    Inspect new clutch disc for proper orientation (most have 'flywheel side' or 'transmission side' markings). Place clutch disc against flywheel with correct orientation and insert clutch alignment tool through disc hub into pilot bearing/bushing. Position new pressure plate over clutch disc, aligning dowel pins or marks. Install pressure plate bolts hand-tight. Tighten pressure plate bolts in star pattern gradually (2-3 turns each bolt at a time) to proper torque specification. Ensure clutch alignment tool moves freely, then remove tool. Install new release bearing onto transmission input shaft bearing retainer.
11. 11

    Prepare transmission for installation
    Clean transmission input shaft splines and apply very light coat of high-temperature grease. Inspect input shaft seal for damage and replace if necessary. Verify release bearing is properly seated on input shaft retainer. Apply small amount of grease to release bearing contact points. Clean transmission bellhousing mating surface thoroughly. Position transmission on transmission jack at proper height and angle for installation.
    ℹ️Use minimal grease on input shaft splines - excess grease can contaminate clutch disc and cause slipping.
12. 12

    Install transmission to engine
    Carefully raise transmission on jack and align with engine. Ensure transmission is level and properly aligned before attempting to mate with engine. Input shaft must align with clutch disc splines - rotate transmission output flange slightly if needed to align splines. Push transmission forward gently while rotating output flange until input shaft engages clutch splines and transmission bellhousing contacts engine block. Never force transmission or use bolts to pull transmission to engine. Install all bellhousing mounting bolts finger-tight first, then torque in star pattern to specification.
    ⚠If transmission does not slide smoothly into place, do not force it. Misalignment can damage clutch disc, input shaft, or pilot bearing. Remove and realign as needed.
13. 13

    Install crossmember and reconnect driveshaft
    Raise transmission slightly with jack and install transmission crossmember. Torque crossmember mounting bolts to specification. Reconnect driveshaft to transmission output shaft and differential flange, aligning marks made during disassembly. Install and torque driveshaft mounting bolts. Reinstall exhaust system components, ensuring proper clearance from driveshaft and heat shields.
14. 14

    Reconnect all electrical, cooler lines, and install starter
    Reconnect all transmission electrical connectors using labels from disassembly. Reconnect transmission cooler lines and torque fittings properly. Install shift cable and adjust as necessary. Reinstall starter motor and torque mounting bolts. Install all bellhousing covers and dust shields. Reinstall transmission splash shields and engine undertray.
15. 15

    Refill transmission fluid and final checks
    Install new crush washer on transmission drain plug and reinstall plug, torquing to specification. Through transmission fill plug or dipstick tube (depending on model), add approximately 10 quarts of ZF Lifeguard 8 transmission fluid. Reconnect negative battery terminal. Start engine and allow to reach operating temperature. Cycle through all gear positions with foot on brake, pausing 2-3 seconds in each position. Check transmission fluid level per manufacturer procedure and adjust as needed. Verify no leaks from transmission, cooler lines, or drain plug.
    ℹ️ZF 8-speed transmissions require specific fill procedure. Some models require scan tool to monitor fluid temperature for proper level check. Consult service manual for exact procedure.

Reassembly

1. Torque all fasteners to specifications in proper sequence - star pattern for flywheel and pressure plate bolts.
2. Use only new torque-to-yield flywheel bolts - never reuse removed bolts.
3. Ensure clutch disc is installed with correct orientation (marked side toward flywheel or pressure plate per manufacturer).
4. Verify driveshaft is aligned with marks made during removal to maintain balance.
5. Double-check all electrical connectors are fully seated and locked.
6. Transmission fluid must be at proper level and temperature for accurate checking - follow ZF procedure.

Verification

• Start engine and verify no abnormal noises from bellhousing area. Listen for rattling that could indicate loose flywheel bolts or failing dual-mass flywheel.
• Test clutch engagement point - should be smooth and consistent without slipping, grabbing, or chatter.
• Drive vehicle and verify smooth shifts through all gears under various loads and speeds.
• Check for vibration at idle and under load - any new vibration may indicate flywheel imbalance or improper installation.
• Verify no fluid leaks from transmission, cooler lines, drain plug, or rear main seal area after test drive.
• Recheck transmission fluid level after test drive when transmission is at operating temperature.
• Verify clutch pedal feel is normal with proper free play and engagement point approximately mid-pedal travel.

More procedures for this vehicle