Upper Control Arm

This procedure covers removal and replacement of the front upper control arm on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including disconnection of the ball joint and control arm mounting points.

Warnings

Tools required

Parts

• Upper Control Arm Assembly × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification
• Control arm mounting hardware kit (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground (do not remove)
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
4. Remove front wheel on side being serviced
5. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes
6. Inspect control arm, ball joint, and mounting points for damage or excessive wear

Procedure

1. 1

   Remove ball joint cotter pin and nut
   Locate the upper ball joint where it connects to the steering knuckle. Use needle nose pliers to straighten and remove the cotter pin from the ball joint castle nut. Discard the old cotter pin. Using an 18mm socket, remove the ball joint nut completely. Do not reuse this nut if it shows signs of damage or thread wear.
2. 2

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the upper ball joint taper from the steering knuckle. Position the separator tool between the control arm and knuckle, then strike or compress to break the taper fit. Avoid damaging the ball joint boot if the control arm is being reused. Once separated, support the knuckle assembly to prevent it from hanging on the lower control arm and brake line.
   ⚠Ball joint taper fit is tight. Use controlled force to avoid damaging surrounding components.
3. 3

   Support control arm
   Place a floor jack with a block of wood under the lower control arm to support the suspension load. Raise slightly to relieve tension on the upper control arm. This prevents the suspension from dropping suddenly when the upper control arm is removed.
4. 4

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the frame/subframe. This bolt passes through the front bushing of the control arm. Using a 19mm socket and breaker bar, remove the front mounting bolt completely. Note the orientation of any washers or spacers for reinstallation.
   ⚠Control arm may shift slightly when bolt is removed. Ensure adequate support.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the frame/subframe. Using a 19mm socket and breaker bar, remove the rear mounting bolt completely. Again, note the orientation of any washers or spacers. The control arm should now be free to remove from the vehicle.
6. 6

   Remove upper control arm
   Carefully maneuver the upper control arm out of the mounting area. It may require some rotation and manipulation to clear the strut assembly, brake lines, and other components. Inspect the removed control arm for worn bushings, torn boots, or damaged ball joint. Inspect mounting points on the frame for corrosion or damage.
7. 7

   Prepare and install new upper control arm
   Clean the mounting points on the frame using a wire brush to remove any corrosion or debris. Compare the new control arm to the old to verify correct part. Install the new upper control arm into position, inserting the ball joint stud into the steering knuckle first. Loosely thread the ball joint nut onto the stud but do not tighten yet.
8. 8

   Install control arm mounting bolts
   Insert the front and rear control arm mounting bolts through the bushings and frame mounting points. Thread bolts in by hand ensuring proper alignment. Snug the bolts but DO NOT TORQUE YET. These bolts must be torqued with the vehicle at ride height (weight on wheels) to prevent bushing preload and premature failure.
   ⚠Do not torque control arm bolts until vehicle is at ride height. Mark these bolts for final torque after wheel installation.
9. 9

   Torque ball joint nut
   Using a torque wrench and 18mm socket, torque the ball joint castle nut to specification. If the castle nut slots do not align with the ball joint stud hole for cotter pin installation, tighten the nut further (up to 1/6 turn additional) until alignment is achieved. Never loosen the nut to align the cotter pin hole. Install a new cotter pin through the castle nut and ball joint stud, then bend the ends of the cotter pin to secure.
   ⚠Always use a new cotter pin. Ensure cotter pin is properly secured to prevent nut loosening.
   Torque spec

   Ball Joint Nut92 Nm (68 lb-ft)
10. 10

    Remove jack support and reinstall wheel
    Carefully lower and remove the floor jack from under the lower control arm. Verify all connections are secure and no tools or parts are left in the wheel well. Reinstall the wheel onto the hub, threading lug nuts by hand initially. Lower the vehicle until the tire just contacts the ground but the suspension is not yet fully loaded.
11. 11

    Torque control arm bolts at ride height
    With the vehicle lowered to the point where the suspension is at normal ride height (tire on ground, full vehicle weight supported), torque the front and rear control arm mounting bolts to specification. This ensures the bushings are not pre-twisted, which would cause premature wear. Use a torque wrench and appropriate socket.
    ⚠This is a critical step. Torquing with suspension hanging will destroy bushings within months.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
12. 12

    Final torque wheel lug nuts
    Fully lower the vehicle to the ground. Using a torque wrench and 21mm socket, torque the wheel lug nuts to specification in a star pattern to ensure even seating of the wheel against the hub. Repeat the star pattern a second time to verify all lugs are properly torqued.
    Torque spec

    Wheel Lug Nuts142 Nm (105 lb-ft)

Reassembly

1. Reassembly is covered in the procedure steps above
2. Ensure all fasteners are torqued to specification at the proper time (control arm bolts at ride height)
3. Verify new cotter pin is properly installed and secured on ball joint
4. Double-check wheel lug nuts are torqued in star pattern

Verification

• Start vehicle and turn steering wheel lock-to-lock while stationary to verify no binding or interference
• Test drive vehicle at low speed in a safe area, listening for any unusual noises from the suspension
• Verify steering returns to center properly and vehicle tracks straight
• After 50-100 miles of driving, re-torque wheel lug nuts to specification
• Schedule a professional alignment as soon as possible, as replacing the upper control arm will affect camber and caster settings

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