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Table of Contents

Section 7: Lubrication and Fluids

Differential Oil

Refer to Figure 7-6 and Figure 7-7

Differential lubrication is essential and must be maintained to ensure long life of the differentials. It is extremely important to use proper type and weight of oil. Also, it is important to check and change oil as outlined in the maintenance schedule below.

NOTE: Running vehicle low on differential oil can damage differential and void its warranty.

Differential Maintenance Schedule

  • Check case housing for damage and possible oil leakage after each use.

  • Check gear lube level every 6 months or every 100 hours (whichever comes first).

  • Change gear lube every 5 years or every 500 hours (whichever comes first).

Differential Oil Type and Capacity See also "Section 10: Specifications and Capacities" on page 40.

  • Type of lubrication: S.A.E 80-90 wt. GL-5 Gear Lube

  • Lubrication capacity: 2 quarts or fill to bottom of check

plug opening. Differential Oil Level Check

Warm oil drains quickly and completely. Drain used oil while it is still warm as follows:

  • 1.

    Park vehicle on a level surface, set park brake, turn off ignition switch and remove switch key.

  • 2.

    Place a suitable container below housing to catch used oil. Remove fill plug, level plug and drain plug.

  • 3.

    Allow used oil to drain completely and then reinstall drain plug and tighten securely with 5 to 15 in. lbs. of torque.

  • 4.

    Dispose of used oil in a manner that is compatible with the environment. Do not throw used oil in the trash, pour it on the ground, or down a drain.

  • 5.

    Fill front and rear differential cases with 2 quarts or to bottom of oil level hole with recommended gear lube. See "Section 10: Specifications and Capacities" on page 40.

  • 6.

    Replace fill plug and oil level plug. Tighten securely with 5 to 15 in. lbs. of torque.

Oil Fill Plug

6 mo/100hrs


Check differential gear lube level at oil level check plugs (See Figure 7-6 and Figure 7-7). Gear lube level should be filled to edge of oil level check hole.

  • 1.

    Prepare vehicle for maintenance as outlined in steps 1-6 on page 22.

  • 2.

    Remove oil level plug and verify oil is level with bottom of plug hole.

  • 3.

    If low on oil, remove fill plug and add new differential oil until oil is level with bottom of fill hole.

  • 4.

    Replace both plugs and tighten securely with 5 to 15 in. lbs of torque.

Differential Oil Change

Oil Level Plug

Figure 7-6

5 yrs/500hrs


Oil Drain Plug

Figure 7-7


4400EX Heavy Duty Off Road Utility Vehicle 720-051M


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