OK, I found this thread and did my own digging around and fixed my problem. I'll give you the steps that I took in the hope it will help others who arrived at this thread searching for a solution for the same problem.
Kia Spectra 1.8L 2002 model - How to change/refill Manual Gearbox Oil
1. Raise vehicle and support it with safety stands. Keep vehicle level when checking oil level.
2. Remove drain plug at bottom of transaxle case and drain fluid into suitable container.
3. Install new washer on drain plug and reinstall plug in case.
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Tightening torque: 29~43 lb-ft (40~58 N·m, 4.0~6.0 kg-m)
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4. Remove oil level plug from transaxle case.
OK, here is what I did...
The oil level plug is hard to reach if you can't jack the car up, so I went in from the top.
I first removed the entire air inlet manifold - easy process of removing bolts and nuts working from the front of the engine bay backward. I disconnected two rubber hoses which connect to the the air filter assembly on the right.
Next I unbolted the air filter assembly (just next to the starter battery), disconnected two air sensor cables and unclamped the air hose from the throttle body up the back of the engine bay and put these out of the way.
I then found that the car battery was in the way, so I disconnected the battery and also removed the battery base-plate.
Finally, I removed a dead-end section of the air intake manifold right next to/under the battery (which had a couple of dead moths in it!) which allowed full access to the gearbox underneath.
The oil level bolt is in a tricky to reach position on the right hand end of the transaxle case, pointing forwards and at an angle down towards the ground. The bolt is quite large, approx. 1 inch in size and is right next to the back-up light switch cable connection. A right angled socket wrench would make life easier, but I used a monkey wrench to crack the bolt.
After unscrewing the bolt by hand, don't forget to check it's washer and replace if there are any cracks.
The gearbox oil level should come right up the the bottom of the oil level plug's hole. The gearbox should take up to 2.8L of oil to completely fill.
5. Add specified amount and type of oil into oil level plug hole until level reaches bottom of hole.
I used a funnel with a flexible extension underneath to fit in the hole, and slowly poured fresh oil into the gearbox until it started overflowing out of the hole. This is how you tell when the oil level is correct. The correct oil type is below, but you can also use GL-5.
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Specified oil: Grade: API Service GL-4
Viscosity: SAE 75W-90(TGO-6)
Capacity: 2.9 US qt (2.7 l, 2.4 lmp qt)
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6. Install new washer on plug and reinstall plug in case.
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Tightening torque: 29~43 lb-ft (40~58 N·m, 4.0~6.0 kg-m)
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7. Warm up vehicle until transaxle oil reaches its normal temperature, then check for leakage of transaxle oil.
Obviously you'll reinstall the air intake assembly and battery first!
8. Lower vehicle.
Hope this helps. If you're unsure about any of this then get a mate to help you. At least you'll know how to get to the refill plug if you need to.
Cheers,
OceanOver
Australia.
*Edit* This thread had been viewed over 4,400 times. Please leave a note if it helped you.
Last edited by OceanOver; 05-21-2011 at 09:52 AM.
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