Product Overview

Summary: This Differential Service Safe Operating Procedure sets out a clear, safe and consistent method for inspecting, servicing and replacing vehicle differentials. It supports Australian businesses to minimise mechanical failures, protect technicians from high-risk tasks under vehicles, and maintain compliant, roadworthy fleets.

Differential servicing involves working beneath vehicles, handling heavy driveline components and managing oils and lubricants that can present both safety and environmental risks. Without a structured, WHS-aligned procedure, workshops are exposed to hazards such as vehicle collapse, crush injuries, contact with hot components, and uncontrolled release of lubricants, as well as inconsistent workmanship that can lead to on-road failures. This Differential Service Safe Operating Procedure provides a step-by-step, defensible method for completing differential inspections, oil changes, seal replacements and related adjustments in a safe and repeatable way.

Designed specifically for Australian automotive and transport operations, this SOP integrates WHS obligations with practical workshop realities. It outlines the correct setup of hoists and stands, safe removal and refitting practices, torque and testing requirements, and controls for exposure to hazardous substances and manual handling risks. By implementing this procedure, workshops and fleet operators can improve safety performance, ensure vehicles remain roadworthy and compliant, and provide clear guidance for technicians of varying experience levels, supporting both quality control and legal due diligence under Australian WHS legislation.

Key Benefits

• Reduce the risk of crush, pinch and impact injuries when working under and around vehicles.
• Ensure consistent, high-quality differential servicing that supports roadworthiness and reliability.
• Streamline technician training with a clear, step-by-step method aligned to Australian WHS requirements.
• Minimise environmental and health risks associated with handling and disposing of differential oils.
• Demonstrate due diligence and compliance during audits, incident investigations and regulator inspections.

Who is this for?

• Automotive Technicians
• Heavy Vehicle Mechanics
• Light Vehicle Mechanics
• Workshop Supervisors
• Fleet Maintenance Managers
• Service Managers
• WHS Advisors in Automotive and Transport
• Plant and Equipment Maintenance Coordinators

Hazards Addressed

• Vehicle collapse due to incorrect hoisting or support
• Crush and pinch injuries from rotating or suspended driveline components
• Exposure to hot surfaces and hot lubricants
• Skin and eye contact with used oils, greases and cleaning solvents
• Slips, trips and falls from oil spills and poor housekeeping
• Musculoskeletal injuries from manual handling of heavy differential components
• Noise exposure during testing and operation of vehicles
• Fire risk from flammable cleaning agents and oil residues

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Legislation and Standards
• 3.0 Definitions (Differential Types, Components and Terminology)
• 4.0 Roles and Responsibilities
• 5.0 Required Qualifications, Training and Competency
• 6.0 Tools, Equipment and Materials
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre-Service Safety Checks and Vehicle Preparation
• 9.0 Hoisting, Jacking and Vehicle Support Procedures
• 10.0 Differential Inspection and Diagnostic Steps
• 11.0 Differential Oil Drain, Inspection and Refill Procedure
• 12.0 Seal, Gasket and Component Replacement Procedure
• 13.0 Reassembly, Torque Settings and Quality Checks
• 14.0 Post-Service Testing and Road Test Requirements
• 15.0 Hazard Identification and Risk Control Measures
• 16.0 Hazardous Substances Handling and Spill Management
• 17.0 Manual Handling and Use of Lifting Aids
• 18.0 Lockout/Tagout and Isolation of Energy Sources
• 19.0 Environmental Controls and Waste Disposal
• 20.0 Emergency Procedures and Incident Response
• 21.0 Recordkeeping, Service Documentation and Compliance
• 22.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• AS/NZS 4024.1: Safety of machinery (series)
• AS 2550.9: Cranes, hoists and winches – Vehicle hoists
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)