Rear Differential

Complete removal and replacement of the rear differential assembly on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including driveshaft disconnection, axle removal, and differential fluid refill.

Warnings

Tools required

Parts

• Rear differential assembly (if replacing) × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM specification
• Axle nut cotter pins or staking compound × 2 — Per torque spec requirements
• Driveshaft mounting hardware × 1 — Replace if damaged
• CV joint bolts (if reusing, inspect) × 12 — Use OEM specification

Fluids

• 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Loosen rear wheel lug nuts while vehicle is on ground.
3. Raise vehicle and support securely on jack stands at all four corners at manufacturer-specified lift points.
4. Remove both rear wheels completely.
5. Spray penetrating oil on all differential mounting bolts, driveshaft bolts, and CV joint bolts. Allow 15-30 minutes to penetrate.
6. Position fluid catch pan under rear differential.
7. Take photos of differential mounting positions and hardware orientation for reference during reassembly.

Procedure

1. 1

   Drain differential fluid
   Locate the differential cover on the rear of the differential housing. Remove the cover bolts in a crisscross pattern using appropriate socket. Carefully pry the cover loose with a flat blade or pry bar, allowing fluid to drain into catch pan. Once drained, remove cover completely and inspect for metal debris or unusual wear patterns. Clean the cover and mounting surface with wire brush.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
2. 2

   Mark and disconnect driveshaft
   Using paint pen or marker, mark the driveshaft flange orientation relative to the differential input flange to maintain balance. Remove the four driveshaft bolts connecting the rear universal joint to the differential pinion flange. Support the driveshaft and carefully lower it, securing it to the exhaust or chassis with mechanic's wire to prevent damage. Inspect U-joint straps for wear.
   ⚠Do not allow driveshaft to hang unsupported as this can damage the center bearing or front U-joint.
   Torque spec

   Driveshaft Bolts79 Nm (58 lb-ft)

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
3. 3

   Remove rear axle nuts
   Remove the cotter pins or unstake the axle nuts on both rear wheel hubs. Use a breaker bar and 32mm or 36mm socket (verify size) to loosen and remove both rear axle nuts. The axle nuts are torqued to 250 Nm and will require significant force. Keep nuts and any washers organized for potential reuse inspection.
   ℹ️New cotter pins or fresh staking is required upon reassembly per specification.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
4. 4

   Disconnect CV joints from differential
   Locate the six CV joint bolts on each side connecting the inner CV joint flanges to the differential output flanges. Remove all twelve bolts (six per side) using appropriate socket. Carefully pull the axle assemblies outward from the differential to disengage the CV joints. Support the axle shafts and tie them to the suspension or chassis to keep them out of the working area. Inspect CV boots for tears or damage.
   ⚠Do not allow axle shafts to hang by CV boots as this can cause joint damage.
   Torque spec

   CV Joint Bolts64 Nm (47 lb-ft)
5. 5

   Disconnect exhaust and heat shields if necessary
   Depending on exhaust routing, it may be necessary to lower or disconnect exhaust components for differential clearance. Remove any heat shields or protective covers attached to the differential or surrounding area. Document mounting positions with photos. On Levante, the rear mufflers and over-axle pipes may require support or partial removal for differential access.
   ⚠Exhaust components may be extremely hot. Allow adequate cooling time before handling.
6. 6

   Support differential with transmission jack
   Position transmission jack or suitable differential support beneath the differential housing. Raise jack until it just contacts the differential and securely supports the weight. Use safety chains or straps to prevent the differential from shifting on the jack. Adjust jack position to ensure balanced support across the differential housing.
   ⚠️Ensure jack is centered and differential is securely strapped before removing mounting bolts.
7. 7

   Remove differential mounting bolts
   Locate all differential mounting bolts connecting the differential housing to the subframe or crossmember. Typically there are 4-6 mounting points. Remove the mounting bolts while supporting the differential weight with the transmission jack. Check for any additional brackets, electrical connectors (ABS sensors, limited-slip solenoids), or breather hoses that must be disconnected. Keep all hardware organized by location.
   ⚠Disconnect any electrical connectors before lowering differential to prevent harness damage.
   Torque spec

   Mounting Bolts28 Nm (21 lb-ft)
8. 8

   Lower and remove differential assembly
   Carefully lower the transmission jack while guiding the differential assembly down and forward to clear the subframe and axle mounting points. The differential may need to be rotated or angled to clear surrounding components. Once clear of the vehicle, carefully transport the differential to a clean work area. Inspect all mounting points on the subframe for damage or excessive wear.
   ⚠️Differential weighs approximately 100 lbs. Use proper lifting technique and get assistance if needed.
9. 9

   Inspect and prepare for installation
   If installing a replacement differential, transfer any necessary components from the old unit (mounting brackets, heat shields, sensors). Clean all mounting surfaces on the subframe thoroughly. Inspect differential mounting bushings and replace if worn or damaged. Verify the replacement differential matches the gear ratio of the original unit by checking identification tags. Apply a thin coat of anti-seize to mounting bolt threads.
   ℹ️Verify gear ratio matches original differential to prevent drivetrain damage and electronic system errors.
10. 10

    Install differential assembly
    Position the differential on the transmission jack and raise it into position beneath the vehicle. Align mounting points with subframe while angling differential as needed for clearance. Reconnect any electrical connectors for ABS sensors or limited-slip actuators. Install all mounting bolts hand-tight first, then torque in a crisscross pattern to specification. Ensure differential is properly seated before final torquing.
    Torque spec

    Mounting Bolts28 Nm (21 lb-ft)
11. 11

    Reconnect CV joints to differential
    Guide both axle assemblies back into position and align the inner CV joint flanges with the differential output flanges. Install all twelve CV joint bolts (six per side) and hand-tighten. Torque the CV joint bolts to specification in a crisscross pattern to ensure even flange seating. Verify axles rotate freely without binding.
    Torque spec

    CV Joint Bolts64 Nm (47 lb-ft)
12. 12

    Install rear axle nuts
    Install the rear axle nuts on both sides with any required washers. Torque the axle nuts to 250 Nm (184 lb-ft) using a torque wrench. Install new cotter pins through the castellated nut and axle shaft holes, or stake the nuts as required by specification. Bend cotter pins properly to prevent backing out.
    ℹ️Never reuse old cotter pins. Always install new pins or apply fresh staking.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
13. 13

    Reconnect driveshaft
    Remove support wire from driveshaft and guide it back into position. Align the reference marks made during disassembly to maintain driveshaft balance. Install the four driveshaft bolts connecting the rear U-joint to the differential pinion flange. Torque the driveshaft bolts to specification. If U-joint straps were removed, install and torque evenly as specified.
    ⚠Misaligned driveshaft marks can cause vibration. Ensure alignment marks match before final torque.
    Torque spec

    Driveshaft Bolts79 Nm (58 lb-ft)

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)
14. 14

    Reinstall differential cover and fill with fluid
    Install new differential cover gasket on the housing. Position the differential cover and install cover bolts, tightening in a crisscross pattern to specification. Using a differential fluid pump, fill the differential with 2.0 quarts of 75W-140 synthetic gear oil through the fill port until fluid reaches the bottom of the fill hole. Install and torque the fill plug. Check for leaks around the cover gasket.
    ℹ️Use only manufacturer-specified 75W-140 synthetic gear oil. Incorrect fluid can damage limited-slip clutches.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
15. 15

    Reinstall wheels and lower vehicle
    Reinstall exhaust components and heat shields if they were removed. Install both rear wheels and hand-tighten lug nuts. Lower vehicle until wheels just contact the ground. Torque wheel lug nuts to 140 Nm (103 lb-ft) in a star pattern. Fully lower vehicle and remove jack stands. Remove parking brake.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Double-check all torque specifications have been met, particularly critical fasteners (axle nuts, CV joint bolts, driveshaft bolts).
2. Verify all electrical connectors are properly seated and secured.
3. Check for any fluid leaks around differential cover and fill plug.
4. Ensure no tools or parts were left in the work area or on the vehicle.

Verification

• Start vehicle and verify no warning lights appear on the dashboard related to ABS or traction control systems.
• With vehicle in park/neutral and parking brake released, rotate rear wheels by hand to verify smooth differential operation without binding or unusual noise.
• Test drive vehicle at low speeds in a safe area, checking for vibrations, unusual noises, or handling issues.
• After test drive, re-inspect all mounting bolts and connections for proper torque and no signs of loosening.
• Check differential fluid level after test drive and inspect cover gasket area for leaks.
• If vehicle is equipped with electronic limited-slip differential, verify proper operation through test drive maneuvers.
• Schedule a follow-up inspection after 50-100 miles to recheck fluid level and inspect for any leaks.

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