Power Steering Rack

Complete removal and replacement of the electric power steering rack assembly on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including tie rod disconnection, subframe access, and rack installation.

Warnings

Tools required

Parts

• Power steering rack assembly × 1 — Use OEM specification
• Rack mounting hardware kit × 1 — May be included with rack
• Tie rod end cotter pins × 2 — Use OEM specification
• Power steering line O-rings × 4 — Use OEM specification
• Steering coupling bolt × 1 — Replace if reusing is not recommended

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Disconnect negative battery terminal and wait 10 minutes for airbag system to discharge
3. Raise vehicle on lift or secure with jack stands at manufacturer-specified lift points
4. Remove both front wheels
5. Spray all fasteners to be removed with penetrating oil and allow to soak for 15 minutes
6. Place alignment marks on steering wheel center position and steering shaft coupling for reference
7. Take photos of all electrical connector orientations and routing paths
8. Verify replacement rack matches original (electric assist type, connector configuration, tie rod length)

Procedure

1. 1

   Remove tie rod ends from steering knuckles
   Remove cotter pins from tie rod end castle nuts and discard. Loosen but do not remove the tie rod end nuts. Use a tie rod end puller or ball joint separator to break the taper between the tie rod and steering knuckle. Remove nuts completely and separate tie rod ends from knuckles. Mark tie rod thread position on outer tie rods for approximate alignment reference during reassembly.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)

   Tie Rod End Nut57 Nm (42 lb-ft)
2. 2

   Disconnect steering shaft coupling
   From inside the vehicle or through the lower dash access panel, locate the steering shaft coupling at the firewall. Make clear alignment marks on both the steering shaft and the rack input shaft using paint pen or scribe. Remove the coupling bolt completely. Use a small pry bar to separate the coupling halves if necessary, being careful not to damage the steering shaft or rack input shaft. Support the intermediate shaft to prevent it from falling.
   ⚠Misalignment of the steering coupling during reinstallation can cause steering binding or premature wear. Ensure alignment marks are clearly visible.
   Torque spec

   Coupling Bolt35 Nm (26 lb-ft)
3. 3

   Disconnect electrical connectors
   Locate the electric power steering motor connector on the rack assembly (typically on the driver's side of the rack). Release the connector locking tab and carefully disconnect the electrical connector. Inspect connector pins for damage or corrosion. Secure the wiring harness out of the way using plastic tie wraps or suspension hooks to prevent damage during rack removal.
4. 4

   Remove stabilizer bar end links (if required for access)
   Depending on subframe design, remove the front stabilizer bar end link bolts from both sides to allow the stabilizer bar to drop for clearance. Support the stabilizer bar with wire or suspension hooks to prevent strain on bushings. This step may not be necessary on all Levante configurations but improves working clearance.
5. 5

   Support front subframe and remove rack mounting bolts
   Position a transmission jack or adjustable jack stand under the front subframe to support its weight. Remove the steering rack mounting bolts that secure the rack to the subframe or crossmember. There are typically two to four mounting bolts depending on rack design. Note the location of any spacers, shims, or alignment dowels for reinstallation. Carefully lower the rack slightly to access any remaining hardware.
   ⚠The rack will become loose once all mounting bolts are removed. Ensure adequate support to prevent the rack from falling.
   Torque spec

   Rack Bolts107 Nm (79 lb-ft)

   Rack Mounting Bolts107 Nm (79 lb-ft)
6. 6

   Remove steering rack assembly
   With an assistant or proper support, carefully maneuver the steering rack assembly out from the vehicle. The rack typically removes toward the driver's side of the vehicle. Rotate and angle the assembly as needed to clear suspension components, the subframe, and body structure. Place the old rack on a clean work surface for comparison with the replacement unit.
7. 7

   Prepare new steering rack for installation
   Unpack the replacement steering rack and verify it matches the original unit in all dimensions, connector types, and tie rod attachment points. Transfer tie rod ends to the new rack if not included, setting them to the same thread depth as marked on the original rack (approximately). Install new O-rings on all hydraulic line connections if present (this vehicle uses electric steering, but verify no hydraulic lines are present). Apply a light coat of clean grease to the rack input shaft splines and mounting bushings.
8. 8

   Install steering rack assembly
   With assistance, carefully maneuver the new steering rack into position, reversing the removal path. Align the rack mounting points with the subframe or crossmember. Install alignment dowels or pins if equipped. Start all rack mounting bolts by hand to ensure proper thread engagement before tightening any bolts. Verify the rack is fully seated in its mounting bushings.
9. 9

   Torque rack mounting bolts
   Tighten the steering rack mounting bolts to specification following the sequence specified in the factory service manual (typically from center outward or in a cross pattern). Verify all mounting hardware is properly seated and there is no gap between the rack and mounting surface. Double-check that no wiring or hoses are pinched between the rack and subframe.
   ℹ️Multiple torque specifications are listed for rack bolts. Verify which bolts are which type according to the service manual and apply the correct torque value.
   Torque spec

   Rack Bolts107 Nm (79 lb-ft)

   Rack Mounting Bolts107 Nm (79 lb-ft)
10. 10

    Reconnect steering shaft coupling
    Ensure the steering wheel is still centered and the rack input shaft is in the center position. Align the steering shaft coupling with the rack input shaft using the alignment marks made during disassembly. Slide the coupling together ensuring the splines are fully engaged. Install the new coupling bolt and tighten to specification. Verify the coupling has no binding through the full range of steering motion by rotating the steering wheel lock-to-lock from inside the vehicle.
    ⚠If alignment marks do not line up, do not force the coupling. Verify rack position and steering wheel position are both centered.
    Torque spec

    Coupling Bolt35 Nm (26 lb-ft)
11. 11

    Reconnect electrical connectors
    Route the power steering wiring harness along its original path and connect the electrical connector to the steering rack motor. Ensure the connector clicks fully into place and the locking tab is engaged. Secure any wiring clips or retainers that were removed during disassembly. Verify no wires are in contact with moving suspension components or hot exhaust parts.
12. 12

    Reinstall stabilizer bar end links (if removed)
    If stabilizer bar end links were removed for access, reinstall them and tighten to specification per the service manual. Ensure the stabilizer bar is properly positioned in its mounting bushings before tightening end link hardware.
13. 13

    Install tie rod ends to steering knuckles
    Clean the tie rod end tapers and steering knuckle bores with brake cleaner. Insert tie rod ends into steering knuckles and install new castle nuts. Tighten nuts to specification. The castle nut slots must align with the cotter pin hole; if they do not align, tighten the nut further (never loosen) until the next slot aligns. Install new cotter pins and bend the ends to secure. Verify tie rod ends have no vertical play after installation.
    ℹ️Castle nuts must be tightened to at least the specified torque and may require additional tightening for cotter pin alignment. Never back off a castle nut to align the pin hole.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)

    Tie Rod End Nut57 Nm (42 lb-ft)

    Tie Rod Nut57 Nm (42 lb-ft)
14. 14

    Reinstall wheels and lower vehicle
    Install both front wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle until the wheels just contact the ground. Torque lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands or lower lift.
    Torque spec

    Wheel Lug Nuts142 Nm (105 lb-ft)
15. 15

    Reconnect battery and initialize steering system
    Reconnect the negative battery terminal and tighten securely. Turn the ignition to the ON position without starting the engine. The electric power steering system may perform a self-calibration; wait for any warning lights to extinguish. Start the engine and verify the power steering warning light is off. Turn the steering wheel slowly lock-to-lock several times to allow the system to learn center position and initialize the electric motor controller.
    ℹ️Some Maserati models require a scan tool to perform steering angle sensor calibration after rack replacement. Consult the factory service manual.

Reassembly

1. All fasteners with specified torque values must be tightened with a calibrated torque wrench
2. Replace all single-use fasteners including cotter pins and any marked torque-to-yield bolts
3. Verify steering wheel returns to center after turning in both directions before road testing
4. Check that no tools or parts were left in the engine bay or wheel wells

Verification

• With vehicle on the ground and engine running, turn steering wheel lock-to-lock and verify smooth operation with no binding, clicking, or unusual noises
• Verify electric power steering warning light is off and steering assist is functioning properly
• Check all mounting bolt torque values with torque wrench to confirm proper tightening
• Inspect for any fluid leaks around connections (should be none on electric steering system)
• Verify tie rod ends have no vertical play and cotter pins are properly installed
• Test drive vehicle at low speed in a safe area to verify steering response and centering
• Schedule four-wheel alignment immediately - vehicle is not safe for highway driving until aligned
• After alignment, perform final road test to verify proper steering feel and tracking

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