Replace the front upper control arm bushings on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD by removing the control arm assembly and installing new bushings or a complete arm assembly.

Warnings

Tools required

Parts

• Front upper control arm bushing kit (or complete control arm assembly) × 1 — Use OEM specification
• Ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at manufacturer lift points
4. Remove front wheel on side being serviced
5. Spray all fasteners with penetrating oil and allow to soak for 15-20 minutes
6. Take photos of control arm orientation and mounting positions for reference during reassembly

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connection at the upper control arm or strut mounting point. Hold the link shaft with an Allen key to prevent rotation and remove the upper nut. Disconnect the link from the control arm assembly to allow greater range of motion during removal.
   Torque spec

   Sway Bar Link64 Nm (47 lb-ft)
2. 2

   Remove ball joint cotter pin and castle nut
   Locate the upper control arm ball joint where it connects to the steering knuckle. Remove the cotter pin completely using pliers or side cutters. Using a 19mm socket, remove the castle nut from the ball joint stud. Do not fully remove until the taper is broken in the next step.
   ℹ️Discard the old cotter pin and castle nut - new ones must be installed during reassembly
   Torque spec

   Ball Joint Nut92 Nm (68 lb-ft)
3. 3

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, break the taper fit between the ball joint stud and the steering knuckle. Insert the tool between the control arm and knuckle, then apply force while striking with a hammer if necessary. Once separated, push the ball joint stud down and out of the knuckle.
   ⚠Wear safety glasses during this step. The ball joint may separate suddenly with significant force
4. 4

   Support control arm and knuckle assembly
   Place a floor jack or support under the lower control arm and knuckle assembly to prevent it from dropping and damaging brake lines or ABS sensors when the upper control arm is removed. Ensure adequate support is in place before proceeding.
5. 5

   Remove front control arm mounting bolt
   Locate the front mounting bolt securing the upper control arm to the frame rail or chassis. This is typically the forward-most attachment point. Using an 18mm or 19mm socket and wrench, remove the bolt completely. Support the control arm as the bolt is withdrawn to prevent sudden movement.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt securing the upper control arm to the frame rail or chassis. Using an 18mm or 19mm socket and wrench, remove this bolt completely. The control arm should now be free to remove from the vehicle. Carefully withdraw the arm while watching for any attached components or wiring.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Inspect and prepare control arm
   With the control arm removed, thoroughly inspect both bushings for cracking, tearing, or separation from the metal sleeve. Clean the mounting areas with a wire brush. If replacing bushings only, mark the orientation of the old bushings before pressing out. If installing a complete new control arm, proceed to reinstallation steps.
8. 8

   Press out old bushings (if applicable)
   Using a hydraulic press and appropriate sized adapters, press the worn bushings out of the control arm. Apply pressure evenly and ensure the control arm is properly supported to prevent distortion. The outer metal sleeve should come out with the rubber bushing. Clean the control arm bore thoroughly before installing new bushings.
   ⚠Ensure control arm is properly supported in press to prevent bending or damage to the arm
9. 9

   Install new bushings
   Apply a thin layer of provided lubricant or soapy water to the new bushing outer sleeve. Orient the bushing correctly according to manufacturer specifications (void or offset positioning matters). Using the hydraulic press, press the new bushing into the control arm bore until fully seated and flush with the arm. Repeat for second bushing position.
10. 10

    Install control arm to chassis mounting points
    Position the control arm (with new bushings or new complete arm) back into the mounting positions on the chassis frame rails. Insert the front and rear mounting bolts through the bushings and chassis brackets. Thread the bolts by hand initially but do NOT torque them yet - they must be torqued with vehicle weight on wheels.
    ⚠Do not torque control arm bolts at this time. Final torque must be applied with vehicle at ride height
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

    Reconnect ball joint to knuckle
    Lift the steering knuckle assembly and align the upper ball joint stud with the tapered hole in the knuckle. Insert the stud fully into the knuckle. Install the new castle nut and torque to specification using a torque wrench. Align the castle nut slots with the ball joint stud hole and install a new cotter pin, bending the ends to secure.
    ℹ️Castle nut slots must align with cotter pin hole. If necessary, tighten nut slightly beyond torque spec to align - never loosen to align
    Torque spec

    Ball Joint Nut92 Nm (68 lb-ft)
12. 12

    Reconnect sway bar link
    Reattach the sway bar link to its mounting point on the control arm or strut assembly. Hold the link shaft with an Allen key to prevent rotation. Install the nut and torque to specification while holding the shaft stationary.
    Torque spec

    Sway Bar Link64 Nm (47 lb-ft)
13. 13

    Install wheel and lower vehicle
    Reinstall the wheel and hand-tighten all lug nuts in a star pattern. Lower the vehicle carefully until the suspension is at normal ride height with weight on the wheels, but keep the vehicle slightly raised. This is the correct position for final torque of control arm bolts.
    Torque spec

    Wheel Lug Nuts142 Nm (105 lb-ft)
14. 14

    Torque control arm bolts at ride height
    With the vehicle weight on the suspension but still accessible from underneath (on jack stands at minimum height or ramps), torque both control arm mounting bolts to specification. This is critical - torquing with suspension hanging will cause premature bushing failure. Use a torque wrench and ensure both bolts reach proper specification.
    ⚠This is a critical step. Control arm bolts MUST be torqued with vehicle weight on suspension at normal ride height
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
15. 15

    Final wheel installation and torque
    Raise vehicle slightly, remove jack stands, and lower vehicle completely to ground. Using a torque wrench, torque all wheel lug nuts to specification in a star pattern. Double-check all fasteners are properly tightened.
    Torque spec

    Wheel Lug Nuts142 Nm (105 lb-ft)

Reassembly

1. Repeat entire procedure for opposite side if replacing both upper control arm bushings
2. Verify all torque specifications have been met, especially control arm bolts torqued at ride height
3. Ensure new cotter pin is properly installed and bent on ball joint castle nut

Verification

• Test drive vehicle at low speed and verify no clunking or unusual noises from front suspension
• Check steering feel and response - should be smooth with no binding
• Perform visual inspection of all fasteners to confirm nothing has loosened
• Schedule four-wheel alignment immediately after this repair - control arm bushing replacement will affect camber and caster settings
• After 50-100 miles, re-torque wheel lug nuts and visually inspect control arm mounting bolts

More procedures for this vehicle