A/t & M/t Control Systems: Other Subaru Outback BR

CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
5. Use SUBARU genuine fluid, grease or equivalent. Do not mix fluid and grease of different grades or manufacturers.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or rigid racks at the specified points.
8. Apply grease onto sliding or revolving surfaces before installation.
9. Before installing the O-ring or snap ring, apply a sufficient amount of fluid to avoid damage and deformation.
10. Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise.
11. Before disconnecting electrical connectors, be sure to disconnect the negative terminal from battery.

GENERAL TOOL

GENERAL TOOL SPECIFICATION

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CONNECTOR TERMINAL REFERENCE

KEY WARNING SWITCH ON AND OFF POSITION

Output signal for key interlock solenoid (unlock)

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Output signal for key interlock solenoid (lock)

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BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT

Note. For the DC power supply circuit, refer to "WIRING DIAGRAMS". Ref. to POWER DISTRIBUTION , Power Supply Circuit .

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DIAGNOSTIC PROCEDURE

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DIAGNOSTIC PROCEDURE

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DIAGNOSTIC PROCEDURE

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1. Set the vehicle on a lift.
2. Shift the select lever to "N" range.
3. Disconnect the ground cable from battery.
4. Lift up the vehicle.
5. Remove the rear exhaust pipe. 2.5 L non-turbo model Ref. to «REMOVAL»(ref-371916-S24336289852010091900000) , Rear Exhaust Pipe. 3.6 L model Ref. to «REMOVAL»(ref-371938-S08736757402010091900000) , Rear Exhaust Pipe.
6. Remove the heat shield cover.
7. Remove the cable from arm assembly.
8. Raise the claw of the clamp and remove the cable.
9. Lower the vehicle.
10. Lower the cover grip AT vertically toward the lever.
11. Remove the clamp grip pin.
12. Remove the grip assembly.
13. Turn over the rubber and remove the console front cover assembly.
14. Remove the console box. Ref. to «REMOVAL»(ref-371913-S18425869832010091900000) , Console Box.
15. Remove the harness clip from the select lever.
16. Disconnect the harness connector.
17. Remove the four bolts to remove the select lever assembly.

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1. Set the select lever to vehicle body.
2. Tighten the four mounting bolts to attach the select lever to the vehicle body. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
3. Connect the harness connector.
4. Install the harness clip to the select lever.
5. Shift the select lever to "N" range.
6. Install the console box and the console front cover assembly. Ref. to «INSTALLATION»(ref-371913-S24975744082010091900000) , Console Box.
7. Accessing from the button side of the grip, attach the clamp grip pin.
8. Install the cover grip AT securely. NOTE: After installation, check that the cover grip AT cannot be detached.
9. Insert the grip assembly to the select lever and press it down until a click is heard.
10. After installation of grip, check the following points. The grip will not come off. The button on the grip operates normally.
11. Lift up the vehicle.
12. Shift the range select lever to "N" range.
13. Secure the cable to the bracket. Ref. to «INSTALLATION»(ref-371931-S15423923542010091900000) , Select Cable.
14. Adjust the select cable position. Ref. to «ADJUSTMENT»(ref-371931-S08692669932010091900000) , Select Cable.
15. After adjustment, confirm that the select lever operates properly at all range positions using the shift lock release button.
16. Install the heat shield cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
17. Install the rear exhaust pipe. 2.5 L non-turbo model Ref. to «INSTALLATION»(ref-371916-S31662490962010091900000) , Rear Exhaust Pipe. 3.6 L model Ref. to «INSTALLATION»(ref-371938-S01176927902010091900000) , Rear Exhaust Pipe.
18. Inspect the following items. If a malfunction is found in the inspection, adjust the select cable or inhibitor switch (CVT model). The shift lock operates normally. Ref. to «SHIFT LOCK OPERATION»(ref-371931-S33608217062010091900000) , INSPECTION, AT Shift Lock Control System. Engine starts when the select lever is in "P" or "N" range, but not in other ranges. Back-up light illuminates when the select lever is in the "R" range, but not in other ranges. Select lever and indicator positions are matched.

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1. Remove the cover grip AT.
2. Remove the button assembly-AT.
3. Remove the rod COM PL.

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1. Remove the spacer.
2. Remove the gasket.
3. Insert a flat tip screwdriver with a thin tip under the connector and disconnect the harness connector from the plate COMPL.
4. Remove the harness from the plate COMPL.
5. Raise the claw with a flat tip screwdriver with a thin tip and remove the solenoid unit.
6. Using a flat tip screwdriver with a thin tip, remove the solenoid unit terminals from the connector.
7. Remove the clamp push nut. NOTE: Replace the clamp push nut with a new part.
8. Pull out shaft control.
9. Remove the clamp push nut. NOTE: Replace the clamp push nut with a new part.
10. Pull out spacer pin guide.
11. Remove the clamp pin.
12. Remove the spacer pin guide.
13. Remove the select lever COMPL from the plate COMPL.
14. Remove the arm assembly.
15. Remove the guide assembly from the select lever COMPL.
16. Remove the rod detent and detent spring from the select lever COMPL.

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1. Disconnect the harness connector from the console front cover assembly.
2. Remove the four screws and remove the indicator assembly from the console front cover assembly.

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1. Clean all the parts before assembly.
2. Apply Multemp D or equivalent to each part.
3. Assemble in the reverse order of disassembly. NOTE: Insert the solenoid unit terminals to the harness connector.
4. After installation, check the following points. The select indicator matches the select lever position when the select lever is changed from "P" range to "D" range. The select lever position and the position mark match each other. Operating force to move the select lever from "P" to "D" range.

"P" RANGE SWITCH

For the removal of "P" range switch, refer to the procedure for AT select lever. Ref. to DISASSEMBLY , Select Lever.

Ref. to AT SELECT LEVER ASSEMBLY , DISASSEMBLY, Select Lever.

NOTE

Refer to "Body Integrated Unit" for removal and installation procedure. Ref. to BODY INTEGRATED UNIT .

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1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Lift up the vehicle.
4. Remove the center exhaust pipe and rear exhaust pipe, (non-turbo model) Ref. to «REMOVAL»(ref-371916-S36161192712010091900000) , Center Exhaust Pipe. Ref. to «REMOVAL»(ref-371916-S24336289852010091900000) , Rear Exhaust Pipe.
5. Remove the center exhaust pipe (rear) and rear exhaust pipe, (turbo model) Ref. to «REMOVAL»(ref-371921-S11272465202010091900000) , Center Exhaust Pipe. Ref. to «REMOVAL»(ref-371921-S14593980742010091900000) , Rear Exhaust Pipe.
6. Remove the heat shield cover.
7. Remove the plate cable assembly.
8. Remove the spring at the MT gear shift cable by expanding it and pulling down, and remove the MT gear shift cable from the gear shift lever assembly. CAUTION: Be careful not to deform the cable inner.
9. Remove the MT gear select cable from the gear shift lever assembly by pulling it in the direction of arrow in the figure. CAUTION: Be careful not to deform the cable inner.
10. Remove the cover cable assembly.
11. Lower the vehicle.
12. Remove the gear shift knob.
13. Remove the console front cover assembly and console box. Ref. to «REMOVAL»(ref-371913-S18425869832010091900000) , Console Box.
14. Remove the bolts, and then remove the gear shift lever assembly from the vehicle. NOTE: The MT gear shift lever cannot be disassembled.

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1. Install the gear shift lever assembly. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
2. Lift up the vehicle.
3. Install the cover cable assembly. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
4. Connect the MT gear shift cable and MT gear select cable. CAUTION: Be careful not to deform the cable inner. Do not twist the cable inner excessively.
5. Install the plate cable assembly. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
6. Install the heat shield cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
7. Install the center exhaust pipe and rear exhaust pipe, (non-turbo model) Ref. to «INSTALLATION»(ref-371916-S02981401052010091900000) , Center Exhaust Pipe. Ref. to «INSTALLATION»(ref-371916-S31662490962010091900000) , Rear Exhaust Pipe.
8. Install the center exhaust pipe (rear) and rear exhaust pipe, (turbo model) Ref. to «INSTALLATION»(ref-371921-S21684767632010091900000) , Center Exhaust Pipe. Ref. to «INSTALLATION»(ref-371921-S14454219392010091900000) , Rear Exhaust Pipe.
9. Lower the vehicle.
10. Install the console front cover assembly and the console box. Ref. to «INSTALLATION»(ref-371913-S24975744082010091900000) , Console Box.
11. Install the gear shift knob.
12. Make sure the gears can be shifted accurately into each gear. Adjust the MT gear select lever, if the gears cannot be shifted correctly. Ref. to «ADJUSTMENT»(ref-371931-S17274144462010091900000) , MT Gear Select Cable.

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1. Check for any deformed, damaged or worn part. Repair or replace as necessary Compare the removed parts with new parts to check if there are damages or not.
2. Check that the lever cannot be moved to the reverse position unless the slider is pulled up.
3. Check that the lever can be moved to the reverse position when the slider is pulled up to maximum.
4. Check that the shift lever returns to the initial position when it is moved to "N" from the condition in 3).

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1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Lift up the vehicle.
4. Remove the center exhaust pipe and rear exhaust pipe, (non-turbo model) Ref. to «REMOVAL»(ref-371916-S36161192712010091900000) , Center Exhaust Pipe. Ref. to «REMOVAL»(ref-371916-S24336289852010091900000) , Rear Exhaust Pipe.
5. Remove the center exhaust pipe (rear) and rear exhaust pipe, (turbo model) Ref. to «REMOVAL»(ref-371921-S11272465202010091900000) , Center Exhaust Pipe. Ref. to «REMOVAL»(ref-371921-S14593980742010091900000) , Rear Exhaust Pipe.
6. Remove the heat shield cover.
7. Remove the clamp cable and take out the MT gear shift cable from the clamp.
8. Remove the dust cover from transmission body.
9. Apply a mark on the top end of the MT gear shift cable.
10. Remove the snap pin from the shift lever COMPL.
11. Remove the shift bracket and MT gear shift cable as a single unit from the transmission body.
12. Remove the plate cable assembly.
13. Remove the spring at the MT gear shift cable by expanding it and pulling down, and remove the MT gear shift cable from the gear shift lever assembly. CAUTION: Be careful not to deform the cable inner.
14. Remove the clamp which holds the MT gear shift cable.
15. Pull out the MT gear shift cable from cover cable assembly.

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1. When replacing the new MT gear shift cable, secure it to shift bracket with the clamps, be careful not to mistake the installing direction.
2. Install the MT gear shift cable and shift bracket as a single unit onto transmission. CAUTION: Do not bend MT gear shift cable at a sharp angle. Do not twist the cable inner excessively. NOTE: When installing the MT gear shift cable, make sure that the mark or blue mark on the cable faces up.
3. Tighten the shift bracket with specified torque. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
4. Install the snap pin.
5. Install the dust cover to the transmission body. Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb)
6. Insert the MT gear shift cable into the cover cable assembly, and secure it with the clamp.
7. Connect the MT gear shift cable.
8. Install the plate cable assembly. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
9. Insert the MT gear shift cable into clamp cable, and install to the transmission. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
10. Install the heat shield cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
11. Install the center exhaust pipe and rear exhaust pipe, (non-turbo model) Ref. to «INSTALLATION»(ref-371916-S02981401052010091900000) , Center Exhaust Pipe. Ref. to «INSTALLATION»(ref-371916-S31662490962010091900000) , Rear Exhaust Pipe.
12. Install the center exhaust pipe (rear) and rear exhaust pipe, (turbo model) Ref. to «INSTALLATION»(ref-371921-S21684767632010091900000) , Center Exhaust Pipe. Ref. to «INSTALLATION»(ref-371921-S14454219392010091900000) , Rear Exhaust Pipe.
13. Lower the vehicle.
14. Make sure the gears can be shifted accurately into each gear.