Rack and Pinion Boots

Replace the rack and pinion boots to prevent contamination and maintain steering system integrity on the 2017 Maserati Levante with electric power steering.

Warnings

Tools required

Parts

• Rack and pinion boot kit (inner and outer boots) × 2 — Use OEM specification
• Boot clamps (small and large) × 8 — Included with boot kit
• Cotter pins for tie rod ends × 2 — Use OEM specification
• Rack grease × 1 — Use Maserati approved grease

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Turn steering wheel to center position and do not move during service
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and secure on jack stands at manufacturer lift points
5. Remove front wheels completely
6. Spray tie rod end nuts and coupling bolt with penetrating oil if corroded
7. Take photos of boot orientation and clamp positions for reference during reassembly

Procedure

1. 1

   Remove tie rod ends from steering knuckles
   Remove cotter pins from tie rod end castle nuts and discard. Loosen tie rod end nuts but do not remove completely. Use tie rod end separator tool to break the taper connection between tie rod end and steering knuckle. Once separated, remove castle nuts completely and set aside tie rod ends. Mark left and right sides to ensure proper reinstallation.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
2. 2

   Access steering rack coupling
   Working from inside the cabin, locate the steering column coupling bolt where the shaft connects to the steering rack input shaft. This may require removing the lower dash panel or knee bolster for access. Mark the alignment position of the coupling on both shafts with paint marker before removal.
3. 3

   Disconnect steering coupling
   Using appropriate socket, remove the coupling bolt connecting the steering column to the rack input shaft. Carefully separate the coupling, being careful not to rotate either shaft. Support the steering column to prevent stress on the shaft.
   ⚠Mark alignment before disconnecting. Improper reassembly can cause steering angle sensor calibration issues requiring dealer reprogramming.
   Torque spec

   Coupling Bolt35 Nm (26 lb-ft)
4. 4

   Remove steering rack mounting bolts
   Locate the steering rack mounting bolts securing the rack assembly to the subframe. There are typically two main mounting bolts/brackets. Remove these bolts while supporting the rack assembly. The rack may be heavy, so use care when removing final mounting points.
   ⚠Support the rack assembly weight before removing final mounting bolt to prevent dropping and damaging components.
   Torque spec

   Mounting Bolts28 Nm (21 lb-ft)
5. 5

   Lower and reposition rack for boot access
   Carefully lower the steering rack assembly enough to access the boots on both sides. You may not need to completely remove the rack from the vehicle. Position the rack to provide clear access to the inner and outer boot clamps on the side being serviced. Work on one side at a time.
6. 6

   Remove old outer boot clamps
   Using boot clamp pliers or side cutters, carefully remove the outer boot clamps from the first side. Note the orientation and position of clamps for reference. Remove both the large clamp at the rack housing end and the small clamp at the tie rod end. Slide the boot off the tie rod shaft.
7. 7

   Remove old inner boot and inspect
   Remove the inner boot clamps and slide the inner boot off the rack. Thoroughly clean the rack shaft with clean rag, inspecting carefully for scoring, pitting, or corrosion. Clean the rack housing boot seating area. Any damage to the rack shaft may require rack replacement as contamination will continue.
   ⚠Inspect rack shaft and inner tie rod threads thoroughly. Damage here indicates contamination has occurred and may require full rack replacement.
8. 8

   Apply grease and install new inner boot
   Pack the rack bellows area with appropriate amount of rack grease per manufacturer specifications (typically 1-2 oz). Slide the new inner boot onto the rack shaft ensuring it seats properly in the rack housing groove. Install the new small clamp at the tie rod end first, then the large clamp at the housing end. Tighten clamps using proper boot clamp tool to ensure secure seal without damaging boot.
9. 9

   Install new outer boot
   Apply thin layer of grease to the tie rod shaft. Slide the new outer boot onto the tie rod, ensuring proper orientation with any breather vents facing downward. Install the small clamp at the tie rod end and the large clamp at the rack housing end. Ensure boots are not twisted and are properly seated before tightening clamps.
10. 10

    Repeat for opposite side
    Reposition the rack as needed to access the opposite side. Repeat steps 6 through 9 for the second side, ensuring equal amounts of grease are applied and boots are properly installed with correct clamp orientation and tightness.
11. 11

    Reinstall steering rack to subframe
    Lift the steering rack back into position on the subframe, aligning mounting brackets to original positions. Install rack mounting bolts and tighten to specification using torque wrench. Ensure rack is seated properly and all mounting hardware is secure.
    Torque spec

    Mounting Bolts28 Nm (21 lb-ft)
12. 12

    Reconnect steering coupling
    Align the steering column coupling to the rack input shaft using the alignment marks made during disassembly. Ensure splines are fully engaged before installing coupling bolt. Install new coupling bolt and torque to specification. Verify coupling is secure and shafts cannot separate.
    ⚠Verify alignment marks match exactly. Misalignment will cause incorrect steering wheel position and may trigger steering angle sensor faults.
    Torque spec

    Coupling Bolt35 Nm (26 lb-ft)
13. 13

    Reconnect tie rod ends to knuckles
    Install tie rod ends back into steering knuckles, ensuring proper left/right orientation. Install tie rod end castle nuts and torque to specification. Install new cotter pins through castle nut slots, ensuring pins are properly bent to prevent backing out. Verify tie rod ends are fully seated in knuckle tapers.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
14. 14

    Reinstall wheels and lower vehicle
    Reinstall front wheels, threading lug nuts by hand first to avoid cross-threading. Snug lug nuts in star pattern while vehicle is still on jack stands. Lower vehicle to ground and torque wheel lug nuts to specification in star pattern.
    Torque spec

    Wheel Lug Nuts142 Nm (105 lb-ft)

Reassembly

1. Reinstall any interior panels or knee bolsters removed for steering coupling access
2. Verify steering wheel is still centered with wheels pointing straight ahead
3. Check all boot clamps are secure and boots are not twisted or damaged
4. Ensure all fasteners are torqued to specification and no tools or parts are left under vehicle

Verification

• Start vehicle and verify no warning lights appear on instrument cluster
• Turn steering wheel lock-to-lock slowly while stationary, listening for any unusual noises
• Check that steering wheel returns to center properly
• Visually inspect all boot clamps are tight and boots show no signs of leakage or displacement
• Test drive vehicle at low speed in safe area, verifying normal steering feel and response
• Verify steering angle sensor is functioning correctly (steering wheel icon should not appear)
• Recheck wheel lug nut torque after 50-100 miles of driving
• Schedule four-wheel alignment to verify toe settings after tie rod end disconnection

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