Power Steering Gear Box

Complete removal and replacement of the power steering gear box (rack and pinion assembly) on a 2017 Maserati Levante with 3.0L V6 Twin Turbo engine, including disconnection of steering coupling, hydraulic lines, and tie rod ends.

Warnings

Tools required

Parts

• Power steering gear box (rack and pinion assembly) × 1 — Use OEM specification
• Power steering line O-rings × 4 — Use OEM specification
• Cotter pins for tie rod ends × 2 — Use OEM specification
• Steering coupling bolt × 1 — Replace if worn or damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and wait 10 minutes for airbag system to discharge
3. Turn steering wheel to center position and verify wheels are straight
4. Lock steering wheel in place using steering wheel holding tool or ignition lock (key to LOCK position)
5. Raise front of vehicle and secure on jack stands at manufacturer-specified lift points
6. Remove both front wheels
7. Mark alignment position of tie rod ends on tie rod threads using paint marker for reference during reassembly
8. Mark steering coupling-to-steering shaft alignment with paint marker before disassembly
9. Place drain pan under steering gear area to catch any residual fluids or debris

Procedure

1. 1

   Remove tie rod ends from steering knuckles
   Remove cotter pins from both tie rod end castle nuts using cotter pin removal tool. Loosen but do not remove the tie rod end nuts. Use ball joint separator or tie rod end puller to break the taper connection between tie rod end and steering knuckle. Once freed, remove nuts completely and separate tie rod ends from knuckles. Keep track of left and right sides.
2. 2

   Disconnect steering intermediate shaft coupling
   From inside the vehicle or through access panel, locate the steering coupling bolt connecting the intermediate shaft to the steering gear input shaft. Verify alignment marks are visible. Remove the coupling bolt completely. Carefully separate the coupling from the steering gear pinion shaft using gentle prying if necessary. Do not damage the splines or coupling.
   ⚠Ensure steering wheel remains locked in centered position during this step to prevent clockspring damage.
3. 3

   Disconnect power steering hydraulic lines (if equipped)
   If your specific Levante variant has hydraulic power steering (verify before proceeding), use crowfoot wrenches to disconnect pressure and return line fittings from the steering gear. Have drain pan positioned to catch any fluid. Cap or plug all open fittings immediately to prevent contamination. Note the position and routing of lines for reinstallation. If vehicle has electric power steering only, skip this step.
   ℹ️Most 2017 Levante models use Electric Power Steering with no hydraulic lines. Verify your configuration.
4. 4

   Remove steering gear mounting bracket bolts
   Locate the steering gear mounting brackets that secure the rack to the subframe or crossmember. These are typically two or more bolts per mounting bracket. Support the steering gear weight with one hand or a transmission jack. Remove all rack mounting bolts while supporting the gear assembly weight.
   ⚠Steering gear assembly weighs approximately 25-35 lbs. Ensure proper support before removing final mounting bolt.
5. 5

   Remove steering gear from vehicle
   With all mounting bolts and connections removed, carefully maneuver the steering gear assembly out of the vehicle. This typically requires angling the unit and removing it through the wheel well or from underneath. Be careful not to damage boots, sensors, or surrounding components. Note the orientation and position for installation of replacement unit.
6. 6

   Prepare new steering gear for installation
   Unpack new steering gear and inspect for shipping damage. Verify part number matches vehicle specification. Remove any protective caps or plugs from ports. Install new O-rings on all hydraulic fittings (if applicable) using light coat of clean power steering fluid or approved lubricant. Ensure rack is in centered position by counting turns lock-to-lock and centering, or matching position to old unit.
   ℹ️New steering gear must be centered before installation to match centered steering wheel position.
7. 7

   Install new steering gear assembly
   Carefully maneuver new steering gear into position, reversing removal path. Align mounting bracket holes with subframe or crossmember mounting points. Install rack mounting bolts finger-tight initially to allow for adjustment. Ensure steering gear input shaft is accessible for coupling connection and properly aligned.
8. 8

   Torque steering gear mounting bolts
   Once steering gear is properly positioned and all mounting bolts are started, torque the rack mounting bolts in a cross-pattern sequence to ensure even loading. Follow manufacturer-specified torque sequence if available in service manual. Verify steering gear is seated properly against mounting surfaces with no gaps.
   ℹ️Verify torque sequence with factory service manual for proper bolt tightening order to prevent rack distortion.
9. 9

   Connect steering intermediate shaft coupling
   Align the steering intermediate shaft coupling with the steering gear input shaft, matching the alignment marks made during disassembly. Ensure splines are fully engaged and coupling is seated properly. Install new coupling bolt and torque to specification. Verify coupling has no play or looseness.
   ⚠Misalignment of coupling can cause steering binding, noise, or loss of steering control. Verify proper engagement before torquing.
10. 10

    Reconnect hydraulic lines (if equipped)
    If vehicle is equipped with hydraulic power steering, install new O-rings on all fittings. Connect pressure and return lines to steering gear ports, following original routing. Hand-tighten fittings first, then use crowfoot wrenches to torque to specification. Ensure lines are not kinked, twisted, or in contact with sharp edges.
    ⚠Cross-threading hydraulic fittings will cause leaks and potential system failure. Start all fittings by hand to ensure proper thread engagement.
11. 11

    Reconnect tie rod ends to steering knuckles
    Thread tie rod ends back onto tie rods to the approximate position marked during disassembly. Insert tie rod end taper into steering knuckle holes. Install tie rod end nuts and torque to specification. If castle nut alignment slots do not align with cotter pin hole, tighten further (never loosen) until next slot aligns. Install new cotter pins and bend tabs to secure.
    ⚠Never loosen castle nut to align cotter pin hole. Always tighten to next alignment position.
12. 12

    Install wheels and lower vehicle
    Reinstall both front wheels, threading lug nuts by hand first to prevent cross-threading. Torque lug nuts to specification in a star pattern. Lower vehicle from jack stands to ground. With vehicle weight on wheels, re-torque lug nuts to final specification in star pattern.

Reassembly

1. Reconnect negative battery terminal
2. Start engine and verify no unusual noises from steering system
3. Turn steering wheel lock-to-lock slowly (engine running if EPS, engine off if hydraulic) to verify full range of motion without binding
4. Check all hydraulic connections for leaks if equipped with hydraulic power steering
5. Verify power steering warning lights are not illuminated on instrument cluster
6. Test drive vehicle at low speeds in safe area to verify steering function before proceeding to alignment shop

Verification

• Verify steering wheel returns to center position after turning
• Confirm no play or looseness in steering wheel during straight-line driving
• Check that steering effort is consistent and appropriate (no heavy spots or binding)
• Inspect all hydraulic connections for leaks if equipped (check after test drive and overnight)
• Verify no unusual noises (clunking, popping, grinding) during steering operation
• Have four-wheel alignment performed at qualified shop and verify all angles are within specification
• After alignment, verify tire wear is even and vehicle tracks straight with no pull to either side
• Confirm power steering warning lights remain off after extended operation

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