Upper Control Arm - Front

Replace the front upper control arm on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including disconnecting the ball joint, removing mounting hardware, and reinstalling with proper torque specifications.

Warnings

Tools required

Parts

• Front upper control arm assembly × 1 — Use OEM specification
• Ball joint cotter pin × 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 front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at manufacturer-approved jacking points
4. Remove front wheel on side being serviced
5. Spray penetrating oil on all control arm fasteners and ball joint nut, allow to soak 10-15 minutes
6. Inspect control arm mounting area and ball joint taper for damage or excessive corrosion

Procedure

1. 1

   Remove ball joint cotter pin and loosen nut
   Use needle nose pliers to straighten and remove the cotter pin from the ball joint castle nut. Using an 18mm socket, loosen the ball joint nut but do not remove it completely at this stage. Leave the nut threaded on 2-3 turns to prevent the knuckle from separating suddenly.
2. 2

   Separate ball joint from knuckle
   Position a ball joint separator or pickle fork between the upper control arm ball joint and the steering knuckle. Strike the tool firmly with a hammer to break the taper fit. Once the joint separates, remove the ball joint nut completely. Support the knuckle to prevent stress on the lower control arm and CV axle.
   ⚠The knuckle will drop slightly when separated. Ensure brake components and CV axle are not stressed.
3. 3

   Support suspension and mark control arm position
   Place a floor jack under the lower control arm or knuckle to support the suspension at ride height. This prevents the coil spring from extending and provides access to the upper control arm bolts. Mark the position of the control arm bolts and bushings relative to the mounting brackets for alignment reference during installation.
4. 4

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the chassis. This bolt passes through the rear bushing. Using the appropriate socket (typically 18mm or 21mm), remove the bolt completely while supporting the control arm. Note the orientation of any washers or spacers.
5. 5

   Remove front control arm mounting bolt
   Remove the front mounting bolt that secures the control arm through the front bushing to the chassis. Support the control arm as you remove this bolt to prevent it from falling. The control arm should now be free to remove from the vehicle.
6. 6

   Remove upper control arm from vehicle
   Carefully maneuver the upper control arm out of the mounting area. It may be necessary to lower or raise the jack supporting the suspension slightly to provide clearance. Inspect the mounting points on the chassis for damage, corrosion, or worn bushing contact surfaces. Clean mounting surfaces with a wire brush if necessary.
7. 7

   Install new upper control arm
   Position the new upper control arm into the mounting brackets, aligning the bushings with the chassis mounting points. Insert the front mounting bolt first, threading it by hand. Then insert the rear mounting bolt. Do not tighten either bolt at this stage - they must be torqued with vehicle weight on wheels for proper bushing pre-load.
8. 8

   Connect ball joint to steering knuckle
   Raise the steering knuckle (using the floor jack if necessary) to align the ball joint stud with the hole in the knuckle. Insert the ball joint stud into the knuckle taper. Thread the new ball joint castle nut onto the stud and tighten hand-tight initially.
9. 9

   Torque ball joint nut and install cotter pin
   Using a torque wrench and 18mm socket, torque the ball joint castle nut to specification. If the cotter pin holes do not align, tighten the nut further (never loosen) until the next castle slot aligns with the hole in the stud. Install a new cotter pin and bend the ends to secure it properly.
   ⚠Never loosen the ball joint nut to align cotter pin holes - always tighten to the next slot.
   Torque spec

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

    Install wheel and lower vehicle
    Reinstall the wheel and thread the lug nuts by hand. Lower the vehicle until the tire just touches the ground but the suspension is not fully loaded. Torque the wheel lug nuts to specification in a star pattern. Then lower the vehicle completely so full weight is on the suspension.
    Torque spec

    Wheel Lug Nuts142 Nm (105 lb-ft)
11. 11

    Torque control arm mounting bolts with weight on wheels
    With the vehicle's full weight on the wheels and suspension at normal ride height, torque both the front and rear control arm mounting bolts to specification. This is critical - torquing the bolts with the suspension unloaded will pre-stress the bushings and cause premature failure. Ensure the vehicle is on level ground and suspension is not compressed or extended.
    ⚠Failure to torque control arm bolts at ride height will result in premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Verify all fasteners are properly torqued according to specifications
2. Check that the new cotter pin is properly installed and secured
3. Ensure no tools or parts were left in the wheel well area

Verification

• Bounce the front suspension several times to settle components and verify no unusual noises
• Visually inspect the ball joint connection and all mounting bolts for proper installation
• Test drive the vehicle at low speed and verify proper steering feel and no clunking noises over bumps
• Schedule a front-end alignment immediately after this repair, as control arm replacement affects camber and caster angles
• Re-check torque on all fasteners after 50-100 miles of driving

More procedures for this vehicle