Transmission R&R - Manual

Complete removal and reinstallation of the manual transmission assembly from a 2017 Maserati Levante with 3.0L V6 Twin Turbo engine, including driveline disconnection, clutch assembly access, and transmission mounting points.

Warnings

Tools required

Parts

• Transmission drain plug crush washer × 1 — Use OEM specification
• Rear differential drain plug copper washer × 1 — Use OEM specification
• Transmission mounting hardware kit × 1 — Use OEM specification
• Driveshaft coupling bolts × 4 — Use OEM specification
• Clutch release bearing × 1 — Replace during R&R
• Transmission input shaft seal × 1 — Use OEM specification
• Shift linkage bushings × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Disconnect negative battery cable and isolate from battery post.
3. Allow exhaust system to cool completely (minimum 2 hours after operation).
4. Raise vehicle on lift or secure on jack stands at all four corners at manufacturer-specified lift points.
5. Remove engine undertray panels and protective covers to access transmission from below.
6. Remove rear wheels to access exhaust hangers and driveshaft components.
7. Install engine support bar across strut towers or attach engine hoist to lifting eyes to support engine weight during transmission removal.
8. Drain transmission fluid from drain plug into appropriate container and inspect for metal contamination.

Procedure

1. 1

   Remove exhaust system components
   Disconnect oxygen sensors and remove exhaust system from catalytic converters rearward. Support exhaust with stands and remove hangers. The center resonator and rear muffler section must be removed to access transmission bellhousing and crossmember mounting points. Label all fasteners for proper reassembly.
2. 2

   Disconnect driveshaft from transmission
   Mark driveshaft-to-transmission flange alignment with paint marker. Remove four driveshaft coupling bolts at transmission output flange. Support driveshaft center bearing and slide driveshaft rearward to separate from transmission output shaft. Secure driveshaft to chassis or remove completely if necessary for clearance.
   ⚠Do not allow driveshaft to hang unsupported by U-joints. This will damage the center support bearing or universal joints.
3. 3

   Disconnect shift linkage and electrical connections
   Remove shift lever assembly from inside cabin by removing center console trim and disconnecting shift rod at transmission selector shaft. Disconnect reverse light switch connector and any speed sensor connectors from transmission case. Remove clutch slave cylinder hydraulic line at transmission bellhousing by releasing quick-disconnect fitting or removing mounting bolts. Do not allow cylinder to hang by hydraulic line.
   ⚠Plug hydraulic line immediately after disconnection to prevent brake fluid contamination and fluid loss. Brake fluid damages paint on contact.
4. 4

   Remove starter motor assembly
   Disconnect starter motor electrical connections (battery cable and signal wire). Remove starter mounting bolts and extract starter motor from bellhousing. This provides access to lower bellhousing bolts and prevents damage during transmission removal.
5. 5

   Support transmission with transmission jack
   Position transmission jack under transmission oil pan with proper adapter or padded saddle. Raise jack until it just contacts transmission and secure with safety chains or straps. Adjust jack position to balance transmission weight evenly. The transmission must be stable and secure before proceeding with mount removal.
6. 6

   Remove transmission crossmember and mounts
   With transmission weight supported by jack, remove transmission mount-to-crossmember fasteners. Remove crossmember-to-chassis bolts and lower crossmember away from vehicle. Inspect transmission mount rubber for deterioration and replace if cracked or oil-saturated.
7. 7

   Remove bellhousing bolts
   Remove all bellhousing-to-engine block bolts. There are typically 6-8 bolts of varying lengths around the bellhousing perimeter. Note bolt locations as different positions use different length bolts. Upper bolts may require extension and universal joint. Ensure all bolts are removed before attempting separation.
   ⚠Some bellhousing bolts may be hidden behind covers or access panels. Verify all fasteners are removed to prevent cracking bellhousing or engine block during separation.
8. 8

   Separate transmission from engine
   With all bolts removed and transmission securely supported, carefully slide transmission straight back away from engine. The input shaft must withdraw cleanly from clutch disc splines and pilot bearing. Move slowly and ensure transmission remains level. If binding occurs, check for missed fasteners or misalignment. Once input shaft clears bellhousing, lower transmission gradually while guiding past chassis components and subframe.
   ⚠️Maintain constant control of transmission jack during lowering. The weight distribution shifts significantly as transmission moves rearward, potentially causing tip or drop.
9. 9

   Inspect clutch assembly and flywheel
   With transmission removed, inspect clutch disc, pressure plate, and flywheel for wear, hot spots, or oil contamination. Check flywheel surface for scoring, heat cracks, or warping. Measure flywheel runout if resurfacing is planned. Replace clutch components if friction material is below specification, contaminated with oil, or shows glazing. Inspect pilot bearing in crankshaft for roughness or wear.
   ⚠If flywheel shows oil contamination, identify and repair source (rear main seal or input shaft seal) before reassembly to prevent immediate clutch failure.
10. 10

    Prepare transmission for installation
    Install new input shaft seal in transmission front cover if replacing. Apply thin coat of high-temperature bearing grease to input shaft splines (do not over-grease as excess will contaminate clutch). Install new clutch release bearing on transmission input shaft sleeve. Verify shift linkage mechanisms move freely and are properly lubricated.
11. 11

    Install clutch assembly if replacing
    If installing new clutch, mount pressure plate and clutch disc to flywheel using clutch alignment tool to center disc on pilot bearing. Install pressure plate bolts and tighten gradually in star pattern to prevent warping pressure plate. Verify alignment tool slides freely through clutch disc hub before final tightening. Remove alignment tool only after transmission is ready for installation.
    ⚠Clutch disc must be oriented correctly with cushion springs or damper toward transmission. Incorrect orientation causes immediate clutch failure.
12. 12

    Install transmission to engine
    Raise transmission into position with jack, aligning input shaft with clutch disc splines and pilot bearing. Insert clutch alignment tool through transmission input shaft to verify alignment if needed. Slide transmission forward carefully, rotating input shaft slightly if necessary to engage splines. Continue until bellhousing seats flush against engine block. Do not force or use bolts to draw transmission into place. Install all bellhousing bolts hand-tight, then torque in star pattern.
13. 13

    Install crossmember and mounts
    Raise transmission jack slightly to align transmission mount with crossmember position. Install crossmember to chassis and torque bolts. Install transmission mount fasteners and torque to specification. Remove transmission jack only after all mounts are secured.
14. 14

    Reconnect all components
    Reinstall starter motor and torque mounting bolts. Reconnect clutch slave cylinder hydraulic line and bleed clutch system if line was opened. Reconnect shift linkage at transmission selector shaft and adjust if necessary. Reconnect all electrical connectors (reverse light switch, speed sensors). Align and install driveshaft to transmission output flange using alignment marks, torquing coupling bolts in star pattern. Reinstall exhaust system components with new gaskets if required. Refill transmission with appropriate fluid through fill plug opening until fluid reaches bottom of fill hole.

Reassembly

1. Torque all fasteners to specified values in proper sequence, particularly flywheel bolts and bellhousing mounting bolts.
2. Verify driveshaft phasing marks are correctly aligned to prevent vibration issues.
3. Bleed clutch hydraulic system completely if slave cylinder was disconnected. Pump clutch pedal until firm resistance is felt with no sponginess.
4. Verify transmission is filled to proper level with correct fluid before operating vehicle.
5. Check shift linkage adjustment and verify all gears engage smoothly before road test.

Verification

• Start engine with clutch pedal depressed and verify no abnormal noises from bellhousing area.
• With engine running, verify clutch disengages completely by shifting through all gears smoothly.
• Check for fluid leaks at transmission drain plug, input shaft seal, and slave cylinder connection.
• Road test vehicle through all gears under light load, verifying smooth engagement and no grinding, slipping, or vibration.
• Verify reverse lights function correctly when reverse gear is selected.
• Recheck all fastener torques after road test, particularly driveshaft coupling bolts and transmission mounts.
• Check transmission fluid level after road test when transmission is at operating temperature.

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