This procedure services the front differential on the AWD-equipped 2017 Maserati Levante by draining and refilling with fresh synthetic gear oil, requiring partial drivetrain disassembly for access.

Warnings

Tools required

Parts

• Front differential cover gasket × 1 — Use OEM specification
• Drain plug washer (if equipped) × 1 — Use OEM specification
• RTV silicone sealant (high-temp) × 1 — Permatex Ultra Grey or equivalent

Fluids

• 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow differential to cool if vehicle was recently operated
3. Loosen wheel lug nuts on both front wheels before raising vehicle
4. Raise front of vehicle and secure on jack stands at manufacturer-specified jacking points
5. Remove both front wheels
6. Remove engine splash shield and underbody panels for differential access
7. Clean exterior of differential housing to prevent contamination during service

Procedure

1. 1

   Disconnect Front Driveshaft
   Mark the driveshaft-to-transfer case flange orientation for proper reinstallation alignment. Remove the four driveshaft bolts connecting the front driveshaft to the front differential input flange. Support the driveshaft and carefully lower it away from the differential, securing it to the chassis with wire or rope to prevent damage.
   Torque spec

   Driveshaft Bolts79 Nm (58 lb-ft)
2. 2

   Disconnect Front CV Axles
   Remove the CV joint bolts on both driver and passenger side axles where they connect to the differential output flanges. There are typically 6 bolts per side. Mark the orientation of each axle for reassembly. Carefully separate the inner CV joints from the differential and secure the axles to prevent strain on the outer CV joints and wheel bearings.
   ⚠Do not allow the axle shafts to hang freely as this can damage the CV joints and boots. Support them with wire or straps.
   Torque spec

   CV Joint Bolts64 Nm (47 lb-ft)
3. 3

   Support and Remove Differential Mounting
   Position a transmission jack or adjustable support under the front differential housing. Remove the differential mounting bolts that secure the assembly to the engine/transmission. There are typically 4-6 mounting bolts. Lower the differential slightly (approximately 2-3 inches) to provide clearance for the cover removal. Do not fully remove the differential from the vehicle.
   ⚠️The differential assembly weighs approximately 40-50 lbs. Ensure support jack is stable and properly positioned before removing mounting bolts.
   Torque spec

   Mounting Bolts28 Nm (21 lb-ft)
4. 4

   Drain Differential Fluid
   Place drain pan beneath the differential. If equipped with a drain plug, remove it and allow fluid to drain completely. If no drain plug is present, proceed to removing the differential cover bolts. Remove all differential cover bolts in a crisscross pattern, then carefully break the cover seal using a rubber mallet or pry bar. Allow all fluid to drain into the pan.
   ⚠Gear oil has a strong sulfur odor and can cause skin irritation. Use gloves and ensure adequate ventilation.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
5. 5

   Remove and Clean Differential Cover
   Once fluid is fully drained, remove the differential cover completely. Inspect the interior of the cover for metal shavings or debris (minor fine particles are normal). Clean the cover thoroughly with brake cleaner and allow to dry. Use a wire brush or gasket scraper to remove all old gasket material and RTV sealant from both the cover and differential housing mating surfaces. Ensure surfaces are completely clean and dry.
6. 6

   Inspect Differential Components
   With the cover removed, visually inspect the ring and pinion gears for unusual wear, pitting, or damage. Check for bearing debris or metal chunks (small amounts of fine metallic paste on the magnetic drain plug are normal). If significant wear or damage is observed, the differential may require professional rebuild before continuing. Wipe clean the magnetic drain plug if equipped.
   ⚠Presence of large metal chunks or severe gear wear indicates internal damage requiring professional assessment before refilling.
7. 7

   Install New Gasket and Reinstall Cover
   Apply a 3mm bead of RTV silicone sealant to the differential housing mating surface, running the bead on the inside of the bolt holes. Alternatively, position the new gasket onto the housing (use small dabs of RTV to hold in place if needed). Carefully position the differential cover onto the housing, aligning all bolt holes. Install all differential cover bolts hand-tight, then torque in a crisscross pattern to specification.
   ℹ️Allow RTV sealant to cure for at least 15 minutes before filling with fluid. Some RTV products require longer cure times - follow manufacturer instructions.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
8. 8

   Refill Differential with Gear Oil
   Locate the differential fill plug (typically on the front or side of the housing). Remove the fill plug. Using a fluid pump, fill the differential with approximately 2.0 quarts of 75W-140 synthetic gear oil through the fill hole until fluid reaches the bottom of the fill plug opening. Reinstall the fill plug and torque to specification if applicable.
   ℹ️Fill capacity may vary slightly. Fill until fluid begins to seep from the fill hole, indicating proper level.
9. 9

   Reinstall Differential Mounting
   Raise the differential assembly back into its mounting position using the transmission jack. Align all mounting bolt holes and install the mounting bolts. Torque all mounting bolts to specification in a crisscross pattern. Ensure the differential is properly seated against the engine/transmission mounting points.
   Torque spec

   Mounting Bolts28 Nm (21 lb-ft)
10. 10

    Reconnect CV Axles
    Align the CV joint flanges with the differential output flanges using the alignment marks made during disassembly. Install all CV joint bolts for both sides. Torque the CV joint bolts to specification in a crisscross pattern. Verify that the axle shafts are fully seated and that there is no excessive play.
    Torque spec

    CV Joint Bolts64 Nm (47 lb-ft)
11. 11

    Reconnect Front Driveshaft
    Raise the front driveshaft into position, aligning the marks made during removal to ensure proper phasing. Install all four driveshaft bolts connecting the driveshaft to the differential input flange. Torque the driveshaft bolts to specification in a crisscross pattern.
    ⚠Improper driveshaft alignment can cause vibration and premature wear. Ensure alignment marks are matched correctly.
    Torque spec

    Driveshaft Bolts79 Nm (58 lb-ft)
12. 12

    Reinstall Underbody Panels and Wheels
    Reinstall all underbody panels and the engine splash shield that were removed for access. Install both front wheels and hand-tighten the lug nuts. Lower the vehicle to the ground. Torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Double-check all fasteners are torqued to specification, particularly driveshaft and CV joint connections
2. Verify no tools or materials were left in the work area
3. Check for fluid leaks around the differential cover after initial startup

Verification

• Start the engine and allow to idle, then shift through all gear ranges (P-R-N-D-S) while stationary
• Check for fluid leaks around the differential cover and fill plug
• Take a short test drive (5-10 minutes) and listen for unusual noises from the front differential area
• After test drive, re-inspect differential cover and all connections for leaks
• Verify no vibration or driveline noise during acceleration and deceleration
• Recheck wheel lug nut torque after 50-100 miles of driving

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