Ring and Pinion

Remove and replace the rear differential ring and pinion gears on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including differential teardown, gear setup, and backlash adjustment.

Warnings

Tools required

Parts

• Ring and pinion gear set × 1 — Use OEM specification for correct ratio
• Pinion bearing kit (inner and outer bearings with races) × 1 — Use OEM specification
• Carrier bearing set × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Pinion nut × 1 — Use OEM specification - single use
• Pinion depth shim kit × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Gear marking compound × 1 — Standard differential setup compound
• Axle seals (if damaged) × 2 — 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 rear of vehicle and support securely on jack stands at manufacturer-specified lift points
4. Remove both rear wheels
5. Place drain pan under differential
6. Mark driveshaft and differential flange positions for proper reassembly alignment
7. Take photos of axle and differential assembly for reference during reassembly

Procedure

1. 1

   Remove driveshaft and axle shafts
   Remove driveshaft bolts at the differential flange and support driveshaft. Remove CV joint bolts at both rear axle flanges. Use axle puller if necessary to separate CV joints from axle flanges. Support axles to prevent damage to CV boots.
   Torque spec

   Driveshaft Bolts79 Nm (58 lb-ft)

   CV Joint Bolts64 Nm (47 lb-ft)
2. 2

   Drain differential and remove cover
   Remove differential cover bolts starting from the top and working around. Allow gear oil to drain completely into drain pan (approximately 2 quarts). Clean all old gasket material or RTV from cover and housing mating surfaces using a plastic scraper.
   ⚠Gear oil will drain when cover is removed. Position drain pan to catch all fluid.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
3. 3

   Mark and remove carrier assembly
   Mark the bearing caps and housing for proper reassembly orientation. Remove carrier bearing cap bolts and carefully remove bearing caps. Install case spreader tool on differential housing per manufacturer instructions. Spread case only enough to remove carrier assembly (typically 0.010 inch maximum). Remove carrier assembly with ring gear attached. Remove case spreader immediately to prevent housing distortion.
   ⚠️Do not over-spread the differential case. Maximum spread is typically 0.010 inch. Excessive spreading will permanently damage the housing.
4. 4

   Remove pinion gear assembly
   Mark pinion nut position relative to pinion shaft for preload reference. Hold pinion flange and remove pinion nut (note: this is a single-use nut). Use a puller to remove pinion flange. Carefully tap pinion shaft rearward to remove from housing along with inner bearing, spacer, and preload shim. Note original shim thickness for reference. Remove pinion seal and outer bearing race.
   ℹ️Record the pinion nut position and number of threads exposed. This provides a starting reference for preload setup during reassembly.
5. 5

   Remove ring gear and bearings from carrier
   Remove ring gear bolts from carrier using cross-pattern loosening sequence. Tap ring gear off carrier using brass drift if necessary. Use bearing puller to remove carrier bearings from carrier assembly. Remove and note side bearing shims for reference. Press out inner and outer pinion bearing races from housing using appropriate driver.
6. 6

   Install new pinion bearing races and determine pinion depth
   Press new inner and outer pinion bearing races into housing using bearing race driver, ensuring they are fully seated. Install pinion depth gauge tool per manufacturer instructions. Using dial indicator, measure pinion depth and compare to variance number etched on new pinion head (typically +/- in thousandths). Calculate required pinion depth shim thickness. Install selected depth shim on pinion shaft.
   ℹ️The variance number on the pinion head (example: +3 or -2) indicates how many thousandths of an inch the pinion depth differs from nominal. This must be factored into shim selection.
7. 7

   Install pinion gear and set bearing preload
   Install inner pinion bearing onto shaft. Install pinion into housing with calculated depth shim. Install outer pinion bearing, new collapsible spacer (if equipped), pinion seal, and pinion flange. Install new pinion nut and tighten gradually while checking pinion bearing preload with inch-pound torque wrench. Target preload is typically 15-25 inch-pounds for new bearings. Rotate pinion several times between checks to seat bearings. Once correct preload is achieved, verify pinion rotates smoothly without binding.
   ⚠The collapsible spacer (if equipped) can only be crushed once. If preload is exceeded, spacer and pinion nut must be replaced and process restarted. Approach target preload gradually.
8. 8

   Install ring gear on carrier
   Clean carrier and ring gear mating surfaces thoroughly. Heat ring gear in oven to approximately 200°F to ease installation if necessary. Install ring gear on carrier, aligning bolt holes. Install new ring gear bolts with thread locker and tighten in cross-pattern sequence to manufacturer specification (typically 90-110 Nm but verify with service manual). Allow to cool if heated.
9. 9

   Install carrier bearings and determine shim requirements
   Press new carrier bearings onto carrier assembly. Install carrier assembly into housing without shims initially. Use case spreader if necessary. Measure side bearing preload requirements and ring gear backlash clearance using dial indicator. Calculate required shim thickness for both sides to achieve proper backlash (typically 0.006-0.010 inch) and bearing preload. Remove carrier and install calculated shims behind each carrier bearing.
   ℹ️Backlash specification is critical. Too tight causes gear noise and overheating. Too loose causes clunking and premature wear. Target is typically 0.006-0.010 inch but verify for specific gear set.
10. 10

    Install carrier assembly and verify backlash
    Install carrier assembly with shims into housing using case spreader as needed. Install bearing caps in original marked positions. Tighten bearing cap bolts gradually in cross-pattern to specification. Check ring gear backlash at 4 points around the gear using dial indicator on ring gear tooth. Backlash should be within specification and vary no more than 0.002 inch around the gear. Adjust shims if necessary by moving thickness from one side to the other.
11. 11

    Check gear tooth contact pattern
    Apply gear marking compound to 6-8 teeth on ring gear. Rotate pinion through several complete revolutions in both directions while applying light resistance. Examine contact pattern on gear teeth. Pattern should be centered on tooth face for both drive and coast sides. Adjust pinion depth shims if pattern is too high or low on tooth. Adjust backlash shims if pattern is too far toward toe or heel of tooth. Repeat until proper pattern is achieved.
    ℹ️Proper gear tooth contact pattern is essential for quiet operation and gear longevity. Pattern should cover 50-60% of tooth surface and be centered. Consult gear manufacturer pattern chart for exact specifications.
12. 12

    Perform final backlash and preload verification
    With proper tooth contact confirmed, verify final backlash at multiple points around ring gear is within specification. Check that pinion rotates smoothly with correct preload. Verify all bearing cap bolts are torqued to specification. Verify ring gear runout is within 0.003 inch using dial indicator if concern exists about carrier or ring gear.
13. 13

    Install differential cover and refill
    Clean differential cover and housing mating surfaces thoroughly. Apply thin bead of RTV silicone or install new gasket per manufacturer specification. Install cover and tighten bolts in cross-pattern sequence to specification. Allow RTV to cure for minimum 30 minutes before filling. Fill differential with 2 quarts of 75W-140 synthetic gear oil through fill plug until oil reaches bottom of fill hole. Install fill plug.
    ℹ️Use only specified 75W-140 synthetic gear oil. Incorrect fluid will cause premature gear wear and failure.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
14. 14

    Reinstall driveshaft and axles
    Align driveshaft to differential flange using marks made during disassembly. Install driveshaft bolts with thread locker and torque to specification in cross-pattern. Install CV joints to axle flanges, aligning marks if made. Install CV joint bolts and torque to specification. Verify axles rotate freely and CV joints are fully seated.
    Torque spec

    Driveshaft Bolts79 Nm (58 lb-ft)

    CV Joint Bolts64 Nm (47 lb-ft)
15. 15

    Install wheels and perform final checks
    Install rear wheels and hand-tighten lug nuts. Lower vehicle to ground. Torque wheel lug nuts to specification in star pattern. Check differential cover for leaks. Test drive vehicle at low speed initially to verify proper operation, listening for abnormal noise or vibration. Perform highway test to verify quiet operation under load. Recheck differential fluid level and cover for leaks after test drive.
    ⚠Initial test drive should be at low speeds in safe area. Any grinding, whining, or clunking noise indicates improper setup requiring immediate investigation.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all bearing races are fully seated and bearings are properly installed
2. Verify pinion depth shim and bearing preload are correct before final assembly
3. Confirm ring gear backlash is within specification at all measurement points
4. Use thread locker on all fasteners as specified
5. Allow RTV sealant to cure fully before filling with gear oil
6. Recheck all torque specifications after initial test drive

Verification

• Verify differential fluid level is correct at fill plug hole
• Check for fluid leaks at differential cover and pinion seal
• Test drive at various speeds confirming no abnormal noise, vibration, or clunking
• Verify smooth acceleration and deceleration with no gear whine
• After 50-100 miles, recheck differential fluid level and inspect for leaks
• Listen for any gear noise that may develop during break-in period
• Monitor differential temperature during initial operation - excessive heat indicates improper setup

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