Transfer Case Chain

This procedure covers the removal and replacement of the transfer case chain in a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, requiring drivetrain disassembly and transfer case servicing.

Warnings

Tools required

Parts

• Transfer case chain × 1 — Use OEM specification
• Transfer case gasket/seal kit × 1 — Use OEM specification
• Transfer case oil seal (input) × 1 — Use OEM specification
• Transfer case oil seal (output) × 1 — Use OEM specification
• Propeller shaft coupling bolts × 8 — Use OEM specification
• Transfer case mounting bolts × 6 — Use OEM specification
• RTV silicone sealant (OEM approved) × 1 — Use OEM specification

Fluids

• ZF Lifeguard 8 — 10 qt
• 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Connect Maserati MDS diagnostic tool and document any stored fault codes related to drivetrain or transfer case operation
2. Raise vehicle on lift and secure with jack stands at all four corners, ensuring adequate working clearance underneath
3. Remove engine undertray and rear undertray panels to access transfer case and propeller shafts
4. Disconnect negative battery cable and wait 10 minutes for system capacitor discharge
5. Mark propeller shaft flanges and transfer case outputs with paint for proper alignment during reassembly
6. Place drain pans under transfer case and transmission to catch all fluids

Procedure

1. 1

   Drain transfer case and transmission fluid
   Locate the transfer case drain plug on the bottom of the unit. Remove drain plug and allow fluid to fully drain into collection pan. If equipped with a separate transfer case fill plug, remove it to speed drainage. Also drain the transmission fluid from the main pan drain plug. Inspect drained fluid for excessive metal particles or debris indicating internal damage.
2. 2

   Remove propeller shafts
   Remove the front propeller shaft by unbolting the coupling at the transfer case output flange and at the front differential input flange. Remove the rear propeller shaft by unbolting at the transfer case rear output and transmission output flange. Support shafts while removing final bolts. Inspect CV joints and slip yokes for wear. Cap all open flanges with plastic bags to prevent contamination.
3. 3

   Disconnect electrical connections and breather hoses
   Disconnect the transfer case motor electrical connector and any speed sensor connectors attached to the transfer case. Disconnect the transfer case breather hose from the vent valve. Label all connections with tape for proper reconnection. Move wiring harnesses away from the transfer case work area.
4. 4

   Support and remove transfer case from transmission
   Position transmission jack or suitable support under the transfer case, securing it with straps or chains. Remove the transfer case mounting bolts that attach it to the transmission adapter housing (typically 6-8 bolts). Carefully pry the transfer case away from the transmission using appropriate pry points. The transfer case may be heavy and awkward to remove due to the chain housing configuration. Lower the transfer case on the jack and move to a clean workbench.
5. 5

   Disassemble transfer case housing
   Mount the transfer case in a holding fixture on a sturdy workbench. Remove the transfer case rear cover bolts and carefully separate the rear housing from the main case. Note the location of any alignment dowels. Remove the transfer case front cover or adapter plate. Take photos during disassembly to ensure proper reassembly sequence. Keep all bolts organized by location.
6. 6

   Remove chain and sprocket assembly
   Remove the snap rings securing the drive and driven sprockets. Use snap ring pliers appropriate for the ring type. Carefully remove the chain from both sprockets. Inspect the sprockets for wear patterns, pitting, or damaged teeth. Check sprocket shaft bearings for roughness or play by rotating by hand. If sprockets show significant wear, they must be replaced along with the chain. Measure sprocket shaft endplay with a dial indicator to verify bearing condition.
7. 7

   Inspect and remove bearings if necessary
   Examine all shaft bearings for roughness, discoloration, or pitting. If bearings require replacement, use a bearing puller to remove them from the shafts and housing. Mark bearing orientation before removal. If using a hydraulic press for bearing removal, support the housing properly to prevent case damage. Clean all bearing bores thoroughly and inspect for scoring.
8. 8

   Clean and inspect all components
   Thoroughly clean the transfer case housing halves, sprockets, shafts, and all internal components with appropriate solvent. Remove all old gasket material and sealant from mating surfaces using a plastic scraper (never metal). Inspect housing for cracks, especially around bolt holes and bearing bores. Inspect all oil passages for blockages. Check shaft surfaces for scoring or wear. Replace any components showing damage or excessive wear.
9. 9

   Install new bearings and seals
   If bearings were removed, press new bearings onto shafts and into housing bores using proper bearing installation tools or a hydraulic press. Ensure bearings are fully seated against shoulders. Install new input and output shaft seals using a seal driver, ensuring they are square and fully seated. Apply a light coating of clean gear oil to seal lips before installation.
10. 10

    Install new chain and sprockets
    Install the drive and driven sprockets onto their respective shafts, aligning any timing marks per manufacturer specifications. Loop the new transfer case chain around both sprockets, ensuring proper orientation and alignment. Check that the chain has appropriate slack (typically 3-5mm deflection at the midpoint between sprockets when pressed). Install new snap rings to secure the sprockets, ensuring they are fully seated in their grooves. Verify chain moves freely without binding by rotating sprockets by hand.
11. 11

    Reassemble transfer case housing
    Apply a thin, even bead of RTV silicone sealant to the housing mating surfaces per manufacturer specifications (typically 2-3mm bead). Install any alignment dowels. Carefully position the rear housing onto the main case, ensuring the chain assembly is not pinched. Install all housing bolts finger-tight first, then tighten in a star pattern working from the center outward. Without torque specifications available, use appropriate torque for the bolt size and thread engagement (typically 20-30 Nm for M8 bolts). Install the front cover or adapter plate with new gasket, following the same tightening pattern.
12. 12

    Reinstall transfer case to transmission
    Apply a thin layer of RTV sealant to the transfer case-to-transmission adapter mating surface. Position the transfer case on the transmission jack and carefully raise into position, aligning the input shaft with the transmission output shaft. Guide the transfer case onto the transmission, ensuring proper shaft engagement. Install all mounting bolts and tighten in a cross pattern. Without specific torque values, use appropriate torque for M10-M12 bolts (typically 40-60 Nm). Remove the support jack once fully secured.
13. 13

    Reconnect propeller shafts and electrical connections
    Install the front and rear propeller shafts, aligning the paint marks made during disassembly to maintain drivetrain balance. Install new coupling bolts if recommended, tightening in a star pattern. Reconnect all electrical connectors to the transfer case motor and sensors, ensuring positive locking engagement. Reconnect the breather hose to the vent valve.
14. 14

    Refill fluids and perform system checks
    Refill the transmission with 10 quarts of ZF Lifeguard 8 fluid through the fill port. If the transfer case has a separate fill port, fill with appropriate gear oil (verify if separate from transmission). Install fill and drain plugs with new crush washers if applicable. Reconnect the battery negative cable. Start the engine and allow it to reach operating temperature while checking for leaks around the transfer case and propeller shaft connections. Use the MDS diagnostic tool to clear any fault codes and perform transfer case adaptation procedures as specified by Maserati.

Reassembly

1. Install engine undertray and rear undertray panels, ensuring all clips and fasteners are secure
2. Check transmission and transfer case fluid levels with the vehicle on level ground and engine running at operating temperature
3. Verify all propeller shaft bolts are torqued to specification and marked alignment marks are correctly positioned
4. Apply thread locker to fasteners as specified for propeller shaft coupling bolts

Verification

• Test drive the vehicle in a safe area, accelerating smoothly from a stop and verifying no abnormal vibrations or noises from the transfer case
• Perform several acceleration and deceleration cycles, listening for chain noise or binding
• Verify proper AWD engagement and disengagement if equipped with selectable modes using the MDS diagnostic tool
• Recheck for leaks around transfer case seals and housing after test drive
• Use MDS diagnostic tool to verify no stored fault codes related to transfer case operation
• Verify proper drivetrain operation in all drive modes (if equipped with multiple modes)
• Recheck fluid levels after test drive and top off if necessary

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