Front Brake Pad Replacement

Replace front brake pads on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including caliper service and proper bedding procedure.

Warnings

Tools required

Parts

• Front brake pad set (OEM or high-performance equivalent) × 1 — Use OEM specification
• Brake pad wear sensors (if equipped) × 2 — Check existing sensors for damage
• Brake caliper slide pin boots (inspect and replace if damaged) × 4 — Use OEM specification

Fluids

• DOT 4 Racing Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Open hood and locate brake fluid reservoir. Remove some fluid with turkey baster or pump to prevent overflow when compressing caliper pistons. Fluid level should be reduced to minimum mark.
3. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground.
4. Lift front of vehicle with floor jack at designated front jacking point and support securely on jack stands at manufacturer-specified support points.
5. Remove front wheels completely and set aside.
6. Inspect brake rotors for scoring, heat cracks, or excessive wear. Measure rotor thickness if gauges available (minimum thickness stamped on rotor hat).

Procedure

1. 1

   Access and inspect brake caliper
   With wheel removed, inspect the brake caliper assembly. Note the position of the brake pad wear sensor wire if equipped (typically on inboard pad). Check caliper slide pins for binding or damage. Spray brake cleaner on caliper and surrounding area to remove brake dust, allowing it to drip into drip pan.
2. 2

   Disconnect brake pad wear sensor
   If equipped, carefully disconnect the brake pad wear sensor electrical connector. Press the release tab and pull connector apart. Do not pull on the wire itself. Trace the wire routing for reinstallation reference.
3. 3

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper (typically 7mm hex). Using the appropriate hex key, remove both slide pin bolts. Support the caliper with one hand as you remove the second bolt to prevent it from falling. The caliper should now pivot upward and away from the rotor.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
4. 4

   Remove caliper and secure
   Carefully lift the caliper up and off the brake pads and rotor. Do NOT let the caliper hang by the brake hose. Secure the caliper to the suspension or chassis using a bungee cord, wire, or caliper hanger. Ensure no strain is placed on the brake hose.
5. 5

   Remove old brake pads and hardware
   Remove the old brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips or shims. Remove the brake pad wear sensor from the old pad if it is integrated (gently pry retention clip). Inspect the caliper bracket for corrosion or damage.
6. 6

   Inspect and clean caliper bracket
   Thoroughly clean the caliper bracket pad contact surfaces with a wire brush, removing all rust, corrosion, and old brake pad material. Clean the slide pin bores. Inspect slide pin boots for tears or damage and replace if necessary. Apply brake cleaner to all surfaces and wipe clean.
7. 7

   Service caliper slide pins
   Remove the slide pins from the caliper bracket. Clean slide pins thoroughly with brake cleaner and inspect for scoring or corrosion. Apply a thin, even coat of high-temperature silicone brake grease to the slide pins. Do NOT use petroleum-based grease. Reinstall slide pins into the bracket, ensuring boots are properly seated.
8. 8

   Compress caliper pistons
   Using a brake caliper piston tool or large C-clamp, carefully compress the caliper pistons fully into the caliper bore. Work slowly and watch the brake fluid reservoir to ensure it does not overflow. If dual pistons, compress both evenly. Ensure pistons retract straight into the bore without cocking to one side.
   ⚠Monitor brake fluid reservoir continuously during this step. Remove additional fluid if necessary to prevent overflow.
9. 9

   Install new brake pads and hardware
   Install any anti-rattle clips or shims onto the new brake pads in the same orientation as removed. If brake pad wear sensor is separate, install it into the new pad per manufacturer orientation (typically inboard pad). Apply a thin layer of silicone brake grease to the pad backing plate contact points on the caliper bracket (where pads slide). Install new brake pads into the caliper bracket.
10. 10

    Reinstall caliper
    Carefully position the caliper over the new brake pads and onto the caliper bracket. Align the slide pin bolt holes. Apply medium-strength threadlocker to the caliper slide pin bolt threads. Insert and hand-start both slide pin bolts. Torque both bolts to specification using torque wrench in a crisscross pattern.
    ⚠Ensure caliper slides freely on slide pins before final torque. If binding is felt, remove caliper and inspect slide pins and boots.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Reconnect brake pad wear sensor
    If equipped, reconnect the brake pad wear sensor electrical connector. Ensure it clicks securely into place. Route the wire in the original path, ensuring it will not contact the rotor or be pinched by the wheel.
12. 12

    Repeat for opposite side
    Repeat steps 1 through 11 for the opposite front brake assembly. Always replace brake pads in complete axle sets (both front wheels).
13. 13

    Reinstall wheels
    Clean wheel mounting surfaces on hub with wire brush. Reinstall front wheels, hand-threading all lug nuts. Lower vehicle until wheels just contact ground but do not carry full weight. Torque lug nuts to specification in a star pattern using torque wrench.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
14. 14

    Restore brake pedal and check fluid level
    With vehicle still supported, slowly pump brake pedal several times until firm pedal is achieved. This reseats the caliper pistons against the new pads. Check brake fluid reservoir and top off to MAX mark with DOT 4 Racing Brake Fluid only. Ensure reservoir cap is secure.
    ⚠️DO NOT start vehicle or attempt to drive until a firm brake pedal is achieved. If pedal remains soft after pumping, there is air in the system or a problem requiring professional diagnosis.
15. 15

    Final lowering and torque check
    Fully lower vehicle to ground and remove jack stands. Perform final torque check on all wheel lug nuts in star pattern. Pump brake pedal firmly several more times and verify firm pedal feel before attempting to move vehicle.

Reassembly

1. Ensure all tools and equipment are removed from under vehicle and wheel wells.
2. Verify wheel lug nuts are torqued to specification on both front wheels.
3. Check brake fluid level is between MIN and MAX marks with reservoir cap secure.
4. Confirm brake pad wear sensor connectors are securely attached if equipped.

Verification

• Start engine and pump brake pedal several times. Pedal should feel firm and consistent. If pedal is soft or spongy, system may require bleeding.
• With vehicle stationary, apply firm brake pressure for 30 seconds and verify pedal does not slowly sink (indicates leak or problem).
• Test drive in safe area at low speed (under 15 mph). Verify brakes engage smoothly without pulling to one side, noise, or vibration.
• CRITICAL: Perform proper brake pad bedding procedure per Maserati specification: 10-15 moderate stops from 40 mph to 10 mph with 30 seconds between stops to allow cooling, followed by normal driving for 200-300 miles avoiding hard stops. This prevents glazing and ensures proper pad-to-rotor transfer layer.
• Re-check brake fluid level after test drive and after first 50 miles of driving.
• Listen for any unusual noises (grinding, squealing beyond initial bedding noise, clicking) that would indicate improper installation.
• After 100 miles, re-torque wheel lug nuts to specification and perform visual inspection of caliper area for leaks or abnormalities.

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