A/t & M/t Control Systems: Removal & Installation Subaru Outback BP

REMOVAL

1. Remove the select lever. Refer to «SELECT LEVER»(ref-208392-S22132093542005120700000) .
2. Remove AT shift lock solenoid and "P" position switch. Refer to «DISASSEMBLY»(ref-208392-S19162379522005120700000) .

INSTALLATION

1. Install AT shift lock solenoid and "P" position switch. Refer to «ASSEMBLY»(ref-208392-S08858236382005120700000) , Select Lever.
2. Install the select lever. Refer to «SELECT LEVER»(ref-208392-S22132093542005120700000) .

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. Disconnect the ground cable from battery.
2. Remove the lower cover.
3. Remove the knee bolster.
4. Disconnect the connector from integrated module.
5. Remove the integrated module.

Install in the reverse order of removal.

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

1. Set the vehicle on a lift.
2. Remove the gear shift knob.
3. Disconnect the ground cable from battery.
4. Remove the console box. Refer to «REMOVAL»(ref-216282-S15871558132006011800000) , Console Box.
5. Remove the clamp.
6. Remove the boot and insulator assembly.
7. Remove the plate ASSY from body.
8. Lift-up the vehicle.
9. Remove the rear exhaust pipe and muffler. Except 2.5 L U5 model Refer to «REMOVAL»(ref-208361-S17585007752005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208361-S00413986862005120700000) , Muffler. 2.5 L U5 model Refer to «REMOVAL»(ref-208369-S20556856332005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208369-S22475579312005120700000) , Muffler. 3.0 L model Refer to «REMOVAL»(ref-208386-S03690047052005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208386-S40817313242005120700000) , Muffler. TURBO model Refer to «REMOVAL»(ref-208376-S18574141742005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208376-S18819972022005120700000) , Muffler.
10. Remove the heat shield cover.
11. Remove the stay from transmission bracket.
12. Remove the rod from joint.
13. Remove the cushion rubber from body.
14. Remove the spring pin, and then extract the joint.
15. Lower the vehicle.
16. Remove the gear shift lever.

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

1. Install the joint to transmission and secure with the spring pin.
2. Insert the gear shift lever from room side. NOTE: After inserting the rod and stay, temporarily put them onto transmission mount.
3. Lift-up the vehicle.
4. Install the joint to shifter arm.
5. Insert the spring pin.
6. Mount the cushion rubber on the body. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
7. Connect the rod to the joint. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
8. Connect the stay to transmission bracket. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
9. Install the heat shield cover. (If equipped)
10. Install the rear exhaust pipe and muffler. Except 2.5 L U5 model Refer to «INSTALLATION»(ref-208361-S21912926732005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208361-S41100021962005120700000) , Muffler. 2.5 L U5 model Refer to «INSTALLATION»(ref-208369-S39698120092005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208369-S32210117812005120700000) , Muffler. 3.0 L model Refer to «INSTALLATION»(ref-208386-S39855252692005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208386-S35967598162005120700000) , Muffler. TURBO model Refer to «INSTALLATION»(ref-208376-S18278122642005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208376-S42649748292005120700000) , Muffler.
11. Lower the vehicle.
12. Install the plate ASSY to body. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
13. Install the boot and insulator assembly to vehicle in proper direction.
14. Install the clamp.
15. Install the console box. Refer to «INSTALLATION»(ref-216282-S01630313832006011800000) , Console Box.

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

1. Disassemble the lock wire.
2. Remove the rod from lever.
3. Remove the snap ring from bushing B, and then disconnect the stay.
4. Remove the boot from gear shift lever.
5. Remove the bushing and cushion rubber from stay.
6. Remove the O-ring, and then disconnect the bushing B.
7. Draw out the spring pin, and then remove the bushing A from gear shift lever.

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

1. Clean all parts before assembly.
2. Mount the bushing and cushion rubber on the stay.
3. Mount each part; boot, O-ring, bushing A, spacer, bushing B, bushing and spring pin on the gear shift lever. NOTE: Always use new O-rings. Apply grease [SUNLIGHT 2 (Part No. 003602010) or equivalent] to the inner and side surfaces of the bushing when installing the spacer.
4. Insert the gear shift lever into boot hole.
5. Install the snap ring and stay to bushing B.
6. Tighten with a new lock wire to the extent that the boot will not come off.
7. Insert the rod into boot hole.
8. Connect the rod to gear shift lever. Tightening torque: 11.8 N.m (1.2 kgf-m, 8.7 ft-lb)
9. Check the swing torque of the rod in relation to gear shift lever.
10. Check that there is no excessive play and that parts move smoothly.

Scheme 42

Scheme 43

1. Check each part (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. Repair or replace any defective part. Determine defective parts by comparing with new parts.
2. Check the swing torque of the rod in relation of gear shift lever. If the torque exceeds specification, replace the bushing or retighten nuts. Swing torque: 3.7 N (0.38 kgf, 0.84 lb) or less

Scheme 44