Transfer Case

This procedure covers the removal and installation of the transfer case on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including driveshaft disconnection, exhaust component removal, and transfer case mounting.

Warnings

Tools required

Parts

• Transfer case output shaft seal × 1 — Use OEM specification
• Transfer case gasket/O-ring kit × 1 — Use OEM specification
• Driveshaft mounting bolts (if corroded) × 8 — Use OEM specification
• Transfer case mounting bolts (if damaged) × 6 — Use OEM specification

Fluids

• ZF Lifeguard 8 — 2 qt

Preparation

1. Raise vehicle on lift or jack stands ensuring level positioning and adequate working clearance
2. Remove engine belly pan and rear undertray panels
3. Apply penetrating oil to all exhaust fasteners and allow to soak for 15 minutes
4. Disconnect negative battery terminal to prevent electrical issues
5. Place reference marks on all driveshaft flanges and corresponding mating surfaces using paint pen
6. Position drain pan under transfer case area

Procedure

1. 1

   Drain transfer case fluid
   Locate the transfer case drain plug on the bottom of the unit. Remove the drain plug and allow fluid to completely drain into the pan. Inspect fluid for metal particles or unusual debris that may indicate internal damage. Remove fill plug to improve drainage flow.
2. 2

   Remove rear driveshaft
   Remove the four bolts securing the rear driveshaft to the transfer case output flange. Support the driveshaft center bearing and remove its mounting bolts from the crossmember. Remove the four bolts at the rear differential flange. Carefully lower and remove the complete rear driveshaft assembly. Cap or cover the transfer case output to prevent fluid spillage.
3. 3

   Disconnect exhaust components
   Remove the heat shields covering the exhaust system near the transfer case. Disconnect the exhaust hangers in the work area. Loosen but do not remove the exhaust clamp at the midsection to allow the exhaust to be moved aside for transfer case clearance. Support the exhaust with a stand or wire to prevent stress on the catalytic converters.
4. 4

   Disconnect electrical connectors
   Locate and disconnect the transfer case actuator electrical connector. Press the locking tab and carefully pull the connector straight out. Disconnect any additional wiring harness clips or brackets attached to the transfer case housing. Position wiring safely away from work area.
5. 5

   Remove transfer case crossmember
   Position the transmission jack under the transfer case with appropriate adapter to support its weight. Raise jack slightly to take tension off the crossmember. Remove the bolts securing the transfer case crossmember to the chassis on both sides. Carefully lower and remove the crossmember from the vehicle.
6. 6

   Disconnect transfer case from transmission
   Locate all transfer case mounting bolts connecting the transfer case to the transmission tailhousing. There are typically 6-8 bolts of varying lengths around the perimeter. Note the position of each bolt for reinstallation. Remove all mounting bolts while supporting the transfer case weight with the transmission jack.
7. 7

   Remove transfer case
   With all mounting bolts removed, carefully slide the transfer case rearward to disengage it from the transmission output shaft. Keep the unit level to prevent binding. Once clear of the transmission, carefully lower the transfer case using the transmission jack. Maneuver the unit out from under the vehicle, being careful of exhaust components and surrounding structures.
8. 8

   Inspect and prepare mating surfaces
   Inspect the transmission output shaft for damage, wear, or scoring. Check the transfer case input shaft and splines for wear. Clean all mating surfaces on both the transmission and transfer case using a wire brush and solvent. Remove all old gasket material and ensure surfaces are clean and dry. Inspect the transfer case output seal and replace if showing any signs of leakage or wear.
9. 9

   Install new seals and gaskets
   Install new transfer case mounting gasket or O-rings per manufacturer specifications. Ensure gaskets are properly seated in their grooves. Apply a thin coat of transmission fluid to the transfer case input shaft splines to ease installation. Replace the output shaft seal if removed or showing wear.
10. 10

    Install transfer case to transmission
    Carefully raise the transfer case into position using the transmission jack. Align the input shaft with the transmission output shaft, ensuring proper spline engagement. Slide the transfer case forward onto the transmission, keeping it level to prevent binding. Install all mounting bolts finger-tight, starting with the top bolts to support the weight. Torque all mounting bolts in a cross pattern. Reinstall the crossmember and torque its mounting bolts.
11. 11

    Reconnect exhaust and electrical
    Reposition the exhaust system to its original location and reconnect any hangers that were disconnected. Tighten the exhaust clamp to specification. Reinstall heat shields. Reconnect the transfer case actuator electrical connector, ensuring it clicks into place securely. Reattach any wiring harness clips or brackets.
12. 12

    Install rear driveshaft
    Install the rear driveshaft assembly by aligning the reference marks made during disassembly. Install the four bolts at the rear differential flange first, hand-tightening only. Install and torque the driveshaft center bearing bolts to the crossmember. Finally, install the four bolts connecting the front of the driveshaft to the transfer case output flange, aligning reference marks. Torque all driveshaft bolts in a cross pattern.
13. 13

    Refill transfer case fluid
    Using a fluid pump, add ZF Lifeguard 8 transmission fluid through the fill hole until fluid begins to flow out of the fill opening, indicating proper level. Allow fluid to settle for a few minutes and top off if necessary. Install and torque the fill plug. Install the drain plug with new crush washer if equipped.

Reassembly

1. Reinstall all undertray panels and belly pan, ensuring all clips and fasteners are secure
2. Reconnect negative battery terminal
3. Lower vehicle from lift or jack stands
4. Clear any fault codes from the vehicle's computer system using appropriate diagnostic tool

Verification

• Start the engine and allow to reach operating temperature while monitoring for any unusual noises from the transfer case area
• Check for fluid leaks around the transfer case mounting surfaces and output shaft seal
• Test drive the vehicle and verify proper operation in all drive modes if applicable
• Verify no vibration or driveline noise during acceleration and deceleration
• After test drive, recheck fluid level and inspect again for leaks
• Verify no warning lights or fault codes related to transfer case operation

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