Maserati - Ghibli M157 - Service Manual - 2016 - 2016

Maserati Technical Bulletin Date: November 29th, 2016 Bulletin No. MAS001052 – Rear Differential Inspection_US Recall Campaign ‐ 328 Supersedes: N/A Model: Quattroporte (M156) and Ghibli (M157) Model Year: 2017 Subject: Vehicle Safety Recall Campaign 328 – Rear Differential Inspection MASERATI SAFETY RECALL BULLETIN PERFORM THE PROCEDURE OUTLINED IN THIS TECHNICAL BULLETIN ON ALL AFFECTED NEW VEHICLES BEFORE CUSTOMER DELIVERY OR FOR VEHICLES ALREADY SOLD AND DELIVERED THE NEXT TIME THE VEHICLE IS IN THE SHOP FOR MAINTENANCE OR REPAIRS. Maserati dealers must ensure recalls are completed after having been notified by Maserati North America, Inc. (MNA) that a safety-related defect or noncompliance exists in any motor vehicle or item of replacement equipment in the dealer’s possession at the time of notification. In MNA's case, this notification would typically be made by the issuance of a recall notification in the form of a Technical Bulletin. Under the National Traffic and Motor Vehicle Safety Act of 1966, as amended, if a recall campaign is announced by MNA, dealers must ensure that all recalls on new vehicles and new items of replacement equipment are completed BEFORE delivery to the consumer. This means that dealers may not legally deliver new motor vehicles or new items of replacement equipment to consumers with an open recall. The Safety Act also prohibits dealers from selling or leasing the motor vehicle or item of replacement equipment, unless and until the open recall has been completed BEFORE delivery. This also pertains to vehicles in the Certified Pre-Owned program, and to items of replacement equipment. Finally, MNA dealers should not sell or use parts that have been recalled by MNA. Please follow the specific instructions provided by MNA on the return or disposition of any parts. © 2016 Maserati North America, Inc. AfterSales www.maseratiusa.com All rights reserved. Reproduction or translation in whole or in part is not permitted without authorization from the publisher. Printed in USA Description of Vehicle Safety Recall 328 Maserati S.p.A. and MNA have determined that the above described vehicles were manufactured with a rear differential unit pinion nut that was not torqued correctly. The function of the pinion nut is to provide the axial force required for proper location of the pinion within the differential unit bearing assemblies. A loose pinion nut will result in a reduction or total loss of axial force, as well as, insufficient orientation of the pinion itself. A loose pinion nut will potentially have an adverse effect on noise, vibration and harshness (NVH) performance, reduced gear, and bearing life, and can cause a differential fluid leak at the pinion seal. In the most severe cases of a loose pinion nut, axial loads could force the pinion into a differential gear binding condition, which can result in blocking the rotation of the ring gear, and potentially locking the rear wheels, thereby increasing the risk of a vehicle crash. Which Vehicles Are Affected Please refer to ModisCS+ and the attached VIN list at the end of this bulletin for the affected vehicles in the U.S. Vehicle Remedy Information 1. Check that the vehicle is included in this Recall campaign, and that this repair has not been previously performed. 2. Inspect the rear differential pinion nut torque. If a replacement differential is needed, see attachment “A” at the end of this bulletin. 3. The recall procedure is now complete. This repair procedure will be performed free of charge to the customer. Parts Needed For The Recall For this Recall campaign, the rear differential P/N: 670039125 (if needed), must be ordered from the Maserati Parts Department. MAS001052_Recall_328_Rear_Differential_Inspection 2 OPERATING PROC CEDURE E 1. Drive D the vehicle on to a lift. S the park king brake to lock the rear r wheelss. 2. Set 3. Disengage D the t gearbo ox parking lock releasse by pullin ng the cab ble as show wn in section 03.0 02.018 – 02 2 of the Wo orkshop Ma anual and be elow in Fig.1. Fig.1 D the battery (08.20.001 1 – 02 of the e Workshop Manual). 4. Disconnect 5. Lift L the vehic cle. 6. Remove R the e r/s and l/s exhaust ta ailpipes as sshown belo ow and in se ection 01.81.004 0 – 00 and 01.81.005 – 00 0 of the W Workshop Ma anual. a. Remove e the space er bar (Fig.2 2) Fig.2 st clamps (N Num.1, in F Fig.3) b. Loosen the exhaus Fig g.3 Fig.4 c. Remove e the vacum me hose fro om the exha aust change e-over valvve (Fig.4) MAS0010 052_Recall_3 328_Rear_Diffferential_Inspection 3 d. Remove e the hange er bolt from the front o of the silenccer (Fig.5) Fig.5 5 Fig.6 e. Slide the pipe brac cket out of the t vibration n dampene er (Fig.6) f. Remove e the hanger bolt from the rear of the silence er (Fig.7) Fig.7 g. Repeat the above procedures s (Fig’s. 3 th hru 7) to re emove the o other silenccer 7. Remove R the e three scre ews (red arrrows) and t hen remove e the heat sshield off of the rear r differen ntial (1 in Fig.8). Fig.8 MAS0010 052_Recall_3 328_Rear_Diffferential_Inspection 4 8. Using a marrker, make a reference e mark possition (Red line, Fig.9 and 9a) on n the differential flange f (1), the drive shaft s and t he mass d dampener ((2). Then m make cing nuts (ffor re-assem mbly). Rem move the 6 bolts notes of the position off the balanc astening the e drive shafft to the diffferential. fa Reference Mark Fig.9 Fig.9a 9. Remove R the e driveshaft from the differential a and supportt it on a hyd draulic lift as shown in Fig g.10 Fig.10 10. With W a marker, draw a line from one o side of the lock nu ut to the oth her side as shown s in Fig.11. Take e a picture of o the nut b before moving to the ne ext step. Fig.11 MAS0010 052_Recall_3 328_Rear_Diffferential_Inspection 5 11. With a calibrated torque wrench, tighten the lock nut to 245 Nm. (Fig.12) NOTE: Make sure the axles / wheels do not turn during this stage. Fig.12 12. Perform a visual inspection of the nut to make sure it has not moved (Fig.13). Compare it with the picture taken in step 10. If there was any movement of the nut, the differential must be replaced. Refer to section 3.21.001 – 00 of the Workshop Manual and attachment “A” in this bulletin. Fig.13 NOTE: Only perform step 13 if the nut moved and the differential has to be replaced. 13. Perform a visual inspection of the drive shaft cover to make sure there are no bumps or protrusions that may alter the smoothness of the cover (Fig.14). If any bumps or protrusions are found, the drive shaft must be replaced. If replacing the drive shaft, refer to section 3.30.001 of the Workshop Manual. Fig.14 MAS001052_Recall_328_Rear_Differential_Inspection 6 14. Reassemb bly - after In nspection only. (No pa arts replace ed.) a. Re-insta all the drive shaft making sure the e reference mark made e in Fig. 9 is aligned with w the driv ve shaft, the mass dam mpener and d the differe ential. (Fig g.15) Reference Mark Fig.15 b. Install th he drive sha aft bolts in their origina al positions and torque e to 30 Nm (+ + 90°). all all of the parts previously remo oved. c. Re-insta En ntering A Warrantty Claim Complette the warra anty claim as a follows:         CampaignN C umber 328 24 Warranty W Co ode Defect D Code e 063 Code Component C 3.2 21.001 Operation O Code C for Ins spection onlly 3.21.001.9 (1.1h) Operation O Code C for Ins spection and d Replacem ment Differe ential 3.21 1.001.8 (2.1 1h) Operation O Code C for In nspection and a Replaccement Diffferential a and Drive shaft 3.21.001.7 (2.7h) Component C Se ee Parts se ection Code MAS0010 052_Recall_3 328_Rear_Diffferential_Inspection 7 Attachment “A” (Replacing the Differential) 1. Replacing the rear differential a. Position a lift and place a block between the lift and differential. (Fig.1) Fig.1 Fig.2 b. Using special tool p/n: 900000226 (Fig.2), remove the fastening bolts from the chassis to the differential. (Fig.3 and Fig.4) Fig.3 Fig.4 c. Remove the lower bolt from the differential to the rear frame. (Fig.5) Fig.5 MAS001052_Recall_328_Rear_Differential_Inspection 8 d. Lower the lift just enough so that you can carefully pry out the axles as shown in Fig.6 and Fig.7. Fig.6 Fig.7 e. Slowly lower the lift while at the same time removing the axles. (Fig’s. 8 and 9) Fig.8 Fig.9 3. Installing the rear differential a. Re-install all of the parts removed following the removal procedure in reverse order. b. Torque the lower bolt on the differential to the rear frame to 65 Nm. (Fig.10) Fig.10 MAS001052_Recall_328_Rear_Differential_Inspection 9 c. Torque T the rear r fastening bolts (Fig.11 and F Fig.12) betw ween the differential an nd chassis to 190 Nm. Fig.11 Fig.12 d. Place the drive shaftt in the diffe erential flan nge and alig gn the referrence markss made durring remova al (Fig.13 an nd 13a) alo ong with the e mark on the new differentia al (Num. 1 in Fig.13a) and the ma ass dampen ner. (Num.2 2 in Fig.13a a) Reference Mark Fig.13 Fig.13a e. Install th he drive sha aft bolts in their origina al positions and torque e to 30 Nm (+ + 90°). (Fig g.14) Fig.14 4 c. Re-insta all rest of th he parts pre eviously rem moved. d. After roa ad testing, if any vibra ations are observed, ba alance the drive shaft. e. To balance the driv ve shaft, re effer to Secttion 3.30.00 01-35 of the e Workshop p Manual. MAS0010 052_Recall_3 328_Rear_Diffferential_Inspection 10 VIN N List U.S. MAS0010 052_Recall_3 328_Rear_Diffferential_Inspection 11