Steering Coupler

This procedure covers the removal and replacement of the steering coupler (intermediate shaft) connecting the steering column to the steering rack on a 2017 Maserati Levante with 3.0L V6 Twin Turbo engine.

Warnings

Tools required

Parts

• Steering coupler (intermediate shaft) × 1 — Use OEM specification
• Coupling bolt × 1 — Use OEM specification
• Coupling bolt locknut (if separate) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Place wheel chocks behind rear wheels
3. Turn steering wheel to center position and verify front wheels are pointing straight ahead
4. Lock steering wheel using a steering wheel holder or turn ignition to lock position and remove key
5. Disconnect battery negative terminal and wait 3 minutes for system capacitors to discharge
6. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
7. Remove lower engine cover/belly pan if equipped to access steering components
8. Allow engine and exhaust components to cool completely if vehicle was recently driven

Procedure

1. 1

   Access steering coupler from cabin
   Remove the lower steering column cover and trim panels as needed to access the upper portion of the steering coupler where it connects to the steering column. You may need to remove cover screws and carefully pull trim panels to expose the connection point.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Mark coupler alignment
   Using a white paint marker, make alignment marks across the steering column shaft and the upper portion of the steering coupler. Also mark the lower coupler connection to the steering rack input shaft. These marks are critical for maintaining proper steering wheel alignment during reassembly.
   ⚠Accurate alignment marks are essential. Incorrect reassembly will result in an off-center steering wheel and may affect vehicle handling.
3. 3

   Disconnect upper coupler connection
   From inside the cabin, locate the upper coupling bolt that secures the steering coupler to the steering column shaft. Use the appropriate socket to loosen and remove the coupling bolt and any retaining hardware. You may need to spray penetrating oil if the bolt is corroded. Note the orientation of any alignment tabs or flats.
   ⚠Support the coupler when removing the bolt to prevent it from dropping or binding.
   Torque spec

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

   Access lower coupler connection
   Move to underneath the vehicle. Locate the lower steering coupler connection to the steering rack input shaft. This is typically accessed from the driver's side wheel well area or through the front subframe area. Clean the area around the connection with a wire brush if necessary.
   ℹ️The lower connection may be tight in the available space. Use adequate lighting to clearly see the coupling bolt and connection.
5. 5

   Remove lower coupling bolt
   Remove the lower coupling bolt that secures the steering coupler to the steering rack input shaft. Use the appropriate socket and extension as needed. If the bolt is difficult to access, you may need to remove or loosen nearby components for clearance. Verify your alignment marks are still visible.
   Torque spec

   Coupling Bolt35 Nm (26 lb-ft)
6. 6

   Separate and remove steering coupler
   Carefully separate the steering coupler from both the steering column shaft (upper) and steering rack input shaft (lower). You may need to use a pry bar or gently tap the coupler with a soft mallet to break it free from the splines. Slide the coupler off both shafts and remove it from the vehicle. Inspect the splines on both shafts for wear or damage.
   ⚠Do not use excessive force that could damage the steering column or rack input shaft splines. The coupler should slide off once the bolts are removed.
7. 7

   Inspect components
   Inspect the removed steering coupler for wear, cracks, or deteriorated rubber dampers. Check both steering column shaft and rack input shaft splines for damage, wear, or corrosion. Clean the splines with a wire brush and apply a light coat of anti-seize compound. Verify the new steering coupler matches the old unit in design and dimensions.
   ℹ️If splines show significant wear or damage, the steering column or rack may need replacement. Consult a professional if damage is found.
8. 8

   Install new steering coupler
   Position the new steering coupler and align it with your previously made alignment marks. Slide the coupler onto the steering column shaft (upper connection) first, ensuring the splines engage properly and the alignment marks line up. Then align and engage the lower connection to the steering rack input shaft. Verify both connections are fully seated and alignment marks match.
   ⚠The coupler must be installed in the exact same orientation as removed. Misalignment will result in steering wheel being off-center.
9. 9

   Install and torque lower coupling bolt
   Install the new lower coupling bolt through the coupler and into the steering rack input shaft. Hand-tighten first to ensure proper thread engagement. Using a calibrated torque wrench, tighten the coupling bolt to the specified torque value. If a locknut is used, install and torque according to specifications.
   ⚠️Coupling bolts are critical safety components. Use new bolts if specified by manufacturer and torque precisely to specification. Under-torquing can result in coupling separation and loss of steering control.
   Torque spec

   Coupling Bolt35 Nm (26 lb-ft)
10. 10

    Install and torque upper coupling bolt
    From inside the cabin, install the new upper coupling bolt through the coupler and into the steering column shaft. Verify alignment marks still match and the coupler is fully seated on the splines. Hand-tighten the bolt, then use a calibrated torque wrench to tighten to the specified torque value.
    ⚠Ensure the bolt engages the locking feature or locknut if equipped. Double-check torque value after final tightening.
    Torque spec

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

    Verify coupler installation
    With both coupling bolts torqued, physically verify there is no play or movement in the steering coupler connections. Attempt to rotate the steering column shaft slightly (within the locked range) and verify the rack input shaft moves correspondingly with no slack or binding. Check that all alignment marks still correspond correctly.
    ⚠Any play or binding in the coupler indicates improper installation. Do not proceed until the issue is resolved.

Reassembly

1. Reinstall lower steering column covers and trim panels in the cabin, torquing cover screws to specification
2. Reinstall lower engine cover or belly pan if removed
3. Lower vehicle from jack stands safely
4. Reconnect battery negative terminal
5. Start vehicle and verify no warning lights related to steering or electrical systems appear

Verification

• With vehicle still on jack stands and steering wheel unlocked, turn the steering wheel slowly lock-to-lock and verify smooth operation with no binding, clicking, or unusual noises from the coupler area
• Verify steering wheel is centered when front wheels are pointing straight ahead
• Perform a slow-speed test drive in a safe area and verify steering response is normal with no play, vibration, or unusual feedback
• Turn steering wheel fully left and right while stationary and at slow speeds, listening for any abnormal noises from the coupler
• Verify no steering-related warning lights appear on the instrument cluster
• After test drive, re-inspect coupling bolts to ensure they remain tight with no signs of loosening

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