Subframe

Complete removal and installation of the rear subframe assembly on a 2017 Maserati Levante RWD, including disconnection of suspension components, driveshaft, and differential mounting.

Warnings

Tools required

Parts

• Ball joint cotter pins × 2 — Use OEM specification
• Subframe mounting bolts (if corroded) × 4 — Use OEM specification
• Control arm bolts (if damaged) × 4 — Use OEM specification
• Differential output shaft seal (if replacing subframe) × 1 — Use OEM specification
• Subframe bushings (if worn) × 4 — Use OEM specification

Fluids

• 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks at front wheels.
2. Loosen rear wheel lug nuts while vehicle is on ground.
3. Raise vehicle completely and support on jack stands at manufacturer-specified lifting points. Minimum 24 inches of clearance needed.
4. Remove both rear wheels and set aside.
5. Spray all subframe bolts, suspension fasteners, and ball joint nuts with penetrating oil. Allow 15 minutes to soak.
6. Place drain pan under rear differential and remove fill plug to inspect fluid level.
7. Using paint pen or marker, mark position of control arms, subframe mounting points, and adjustable links for reassembly reference.
8. Support rear differential and subframe with transmission jack before beginning disassembly.

Procedure

1. 1

   Disconnect sway bar links
   Locate the sway bar end links on both sides. Hold the ball stud with a 6mm Allen key inserted from the back side to prevent spinning. Using an 18mm wrench, remove the upper nuts securing the sway bar links to the sway bar. Allow links to hang from lower control arms.
   Torque spec

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

   Separate ball joints from knuckles
   Remove the cotter pins from both lower ball joint castle nuts. Using a 22mm socket, loosen but do not fully remove the ball joint nuts. Install ball joint separator tool and apply pressure to separate the ball joint taper from the steering knuckle. Once separated, remove the nuts completely. Support the knuckle assembly to prevent strain on brake hoses and wheel speed sensor wires.
   ⚠Keep ball joint nut threaded on several turns while using separator tool to prevent sudden release and component damage.
   Torque spec

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

   Disconnect rear shock absorbers
   Locate the lower shock absorber mounting bolts at the control arm connection points on both sides. Using appropriate socket, remove the lower strut mounting bolts. Compress shock slightly if needed to relieve tension. Secure shocks with wire or zip ties to prevent hanging on brake lines.
   Torque spec

   Strut Bolts121 Nm (89 lb-ft)
4. 4

   Remove driveshaft from differential
   Mark the driveshaft flange position relative to the differential flange for proper reassembly phasing. Remove the four bolts securing the driveshaft to the rear differential output flange. Support the driveshaft center bearing and carefully slide the front spline section out of the transmission. Have a drain pan ready as differential fluid will leak. Secure driveshaft out of the way. Install a plug or tape over differential output to minimize fluid loss.
   ⚠Do not let driveshaft hang by center bearing support. Damage to rubber mount or U-joints can occur.
5. 5

   Disconnect brake lines and ABS sensors
   Locate the brake line mounting brackets attached to the subframe. Carefully disconnect brake lines from their subframe mounting points without disconnecting the lines themselves - they should remain attached to calipers. Disconnect both rear ABS wheel speed sensor connectors and carefully unclip wiring from subframe routing points. Secure all lines and wiring to the vehicle body with wire or zip ties to prevent damage during subframe removal.
6. 6

   Disconnect differential mounting and breather
   Locate the differential breather hose at the top of the differential housing and disconnect it. Remove any differential-to-subframe mounting bolts or brackets if present on this model. Ensure transmission jack is positioned securely under the differential and subframe center to support the full assembly weight.
   ⚠️Verify transmission jack is centered and stable. The assembly will shift as mounting points are removed.
7. 7

   Disconnect control arm front mounting bolts
   Locate the front mounting bolts for both lower control arms where they attach to the subframe. These are large fasteners that may require significant force. Using a breaker bar and appropriate socket, remove the control arm front mounting bolts on both sides. Note that these bolts pass through bushings and should be kept with their respective sides. Do not remove the rear mounting points yet.
   ℹ️Control arm bolts must be torqued with vehicle weight on suspension at normal ride height during reassembly.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
8. 8

   Remove subframe mounting bolts
   Locate the four main subframe mounting bolts connecting the subframe to the vehicle chassis. These are typically located at the front corners and rear corners of the subframe. Verify transmission jack is securely supporting the subframe weight and positioned to prevent tipping. Beginning with the rear bolts, remove all four subframe mounting bolts slowly. As the last bolt is loosened, carefully control the descent of the subframe using the transmission jack. Lower the subframe assembly approximately 6 inches and check for any remaining connections.
   ⚠️Have an assistant help guide the subframe as it is lowered. The assembly is heavy and awkward to control alone.
9. 9

   Final separation and removal
   Perform a final inspection to ensure all brake lines, wiring, and hoses are clear of the subframe. Verify sway bar is not caught on any components. Slowly lower the subframe assembly completely and roll the transmission jack out from under the vehicle. Inspect all bushings, control arm pivot points, and subframe mounting points for wear or damage. Clean all mounting surfaces on the vehicle chassis before reinstallation.
   ℹ️This is the ideal time to inspect and replace worn bushings, control arms, or differential mounts before reinstallation.

Reassembly

1. Reassembly is reverse of removal with the following critical notes:
2. Install new subframe bushings if originals show any signs of cracking or deterioration.
3. Raise subframe into position using transmission jack. Align all mounting holes before starting bolts.
4. Start all four subframe mounting bolts by hand before tightening any. Torque mounting bolts in a cross pattern to specification.
5. Reconnect control arm front mounting bolts but do NOT torque to final specification until vehicle is at ride height.
6. When reconnecting driveshaft, align the reference marks made during disassembly to maintain driveshaft phasing.
7. Install new cotter pins in ball joint castle nuts and bend properly to secure.
8. Refill rear differential with 2.0 quarts of 75W-140 synthetic gear oil through fill plug until fluid reaches bottom of fill hole.
9. After all fasteners except control arm bolts are torqued, lower vehicle to ground and bounce suspension several times to settle.
10. With vehicle weight on wheels at normal ride height, torque control arm bolts to 165 Nm (122 lb-ft).
11. Torque wheel lug nuts to 142 Nm (105 lb-ft) in a star pattern.
12. Bleed brake system if any brake lines were disconnected or damaged.

Verification

• Check that all fasteners are torqued to specification, paying special attention to critical suspension mounting points.
• Verify differential fluid level is correct and no leaks are present at output shaft seal.
• Verify brake pedal feels firm and normal with no fluid leaks at lines or connections.
• Test drive vehicle at low speed in a safe area and verify no abnormal noises, vibrations, or handling issues.
• Schedule four-wheel alignment immediately. Verify thrust angle, toe, and camber are within specification.
• After 50-100 miles, re-inspect all subframe mounting bolts and control arm bolts for proper torque retention.
• Monitor for any differential fluid leaks or unusual driveline vibrations during the first several hundred miles.

More procedures for this vehicle