Front Differential

This procedure covers the removal and replacement of the front differential assembly on a 2017 Maserati Levante with the 3.0L V6 Twin Turbo RWD configuration.

Warnings

Tools required

Parts

• Front differential assembly × 1 — Use OEM specification
• Differential mounting bolts × 1 — Use OEM specification
• Output shaft seals × 2 — Use OEM specification
• Crush washers for drain/fill plugs × 2 — Use OEM specification
• Driveshaft coupling bolts × 1 — Use OEM specification, typically single-use

Fluids

• 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Verify vehicle VIN and configuration to confirm presence of front differential (RWD models do not have front differentials)
2. If AWD model confirmed, raise vehicle on lift or support securely on jack stands at all four corners
3. Remove engine undertray and protective shields to access front differential area
4. Mark driveshaft and differential flange orientation for proper reinstallation alignment
5. Place drain pan under front differential drain plug location

Procedure

1. 1

   Drain differential fluid
   Locate the front differential drain plug on the bottom of the housing. Clean the area around the drain plug. Remove the drain plug and allow fluid to drain completely into the drain pan. Inspect drained fluid for metal particles or contamination indicating internal damage. Remove the fill plug to allow complete draining and ventilation.
2. 2

   Disconnect front driveshaft
   Support the front driveshaft with a strap or wire. Remove the bolts securing the driveshaft to the front differential input flange. Note the location of any alignment marks. Carefully lower the driveshaft and secure it out of the way with wire or mechanics wire to prevent damage to the CV joints.
3. 3

   Disconnect front axle shafts
   Remove the bolts securing both front axle shafts to the differential output flanges. Mark the position of each shaft for correct reassembly. Support the axle shafts and secure them out of the way to prevent damage to CV boots or joints. Cap or cover the differential output flanges to prevent fluid seepage.
4. 4

   Disconnect electrical connections
   Locate and disconnect any electrical connectors attached to the front differential, including speed sensors or actuator connections if equipped with active torque vectoring. Label connectors if necessary for correct reinstallation.
5. 5

   Remove differential mounting hardware
   Position transmission jack under the center of the front differential assembly. Raise jack slightly to support the weight. Locate all mounting bolts securing the differential to the subframe and crossmember. Note the location and length of each bolt as they may vary. Remove the rear mounting bolts first, then the side mounting bolts, leaving the front bolts for last.
6. 6

   Lower and remove differential
   With all mounting bolts removed, carefully lower the differential assembly using the transmission jack. Guide it clear of any interference points including brake lines, wiring, and suspension components. Have an assistant help guide the assembly during removal. Once clear of the vehicle, roll the jack away and place the differential on a clean work surface.
7. 7

   Inspect and clean mounting surfaces
   Inspect all mounting points on the subframe and crossmember for damage, cracks, or excessive wear. Clean all mounting surfaces with a wire brush and solvent. Inspect all mounting bolt holes for thread damage. Check mounting bushings and replace if worn or cracked.
8. 8

   Prepare new differential for installation
   If installing a remanufactured or replacement differential, verify all mounting points match the original unit. Install new output shaft seals into the differential housing if not pre-installed. Apply a thin coat of gear oil to seal lips. Ensure all plugs are properly installed and torqued.
9. 9

   Install differential assembly
   Position the new or rebuilt differential on the transmission jack. Raise it into position carefully, guiding it past all obstructions. Align the mounting holes with the subframe and crossmember mounting points. Start all mounting bolts by hand to ensure proper thread engagement before tightening any bolts. Install front bolts first, then sides, then rear.
10. 10

    Torque mounting bolts
    Torque all differential mounting bolts to manufacturer specification in a cross-pattern sequence. Since torque specifications are not provided in the database, consult the factory service manual for exact values. Typically these are high-torque applications requiring 70-100 ft-lbs, but verification is critical.
11. 11

    Reconnect axle shafts
    Clean the axle shaft flanges and differential output flanges. Align the marks made during disassembly. Install both front axle shafts to the differential output flanges using new bolts if specified. Torque fasteners to specification per factory service manual.
12. 12

    Reconnect front driveshaft
    Align the driveshaft with the front differential input flange using the alignment marks made during removal. Install new coupling bolts and torque to specification. Ensure proper alignment to prevent driveline vibration.
13. 13

    Reconnect electrical connections
    Reconnect all electrical connectors to sensors and actuators on the differential assembly. Ensure connectors are fully seated and locking tabs are engaged. Verify no wires are pinched or routed incorrectly.
14. 14

    Fill differential with fluid
    Using a fluid pump or squeeze bottle, fill the differential through the fill port with 75W-140 synthetic gear oil. Fill until fluid begins to seep from the fill hole, indicating proper level (approximately 2.0 quarts). Install a new crush washer on the fill plug and torque to specification. Install a new crush washer on the drain plug and torque to specification.

Reassembly

1. Reinstall all protective shields and undertray panels removed during disassembly
2. Lower vehicle to ground and torque wheel lug nuts to specification if wheels were removed
3. Check for any fluid leaks around differential seals and mounting points

Verification

• Start engine and verify no unusual noises from the front differential area
• Test drive vehicle at low speeds and verify smooth operation without vibration or binding
• Check for proper AWD engagement if so equipped by performing lock test per manufacturer procedure
• Re-inspect differential for leaks after test drive, particularly at output seals and drain/fill plugs
• Verify differential fluid level after test drive and top off if necessary

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