Subaru Outback (BR): MT Gear Select Cable

A: REMOVAL

CAUTION: Always use new MT gear select cable if the cable is removed from selector lever COMPL of transmission side.

1) Disconnect the ground cable from battery.

2) Remove the ten clips and remove the grille bracket.

3) Remove the air intake duct.

• Non-turbo model <Ref. to IN(H4SO)-9, REMOVAL, Air Intake Duct.>
• Turbo model <Ref. to IN(H4DOTC)-12, REMOVAL, Air Intake Duct.>

4) Remove the intercooler and the intercooler stay. (turbo model) <Ref. to IN(H4DOTC)-17, REMOVAL, Intercooler.>

5) Remove the air intake boot assembly. (non-turbo model) <Ref. to IN(H4SO)-8, REMOVAL, Air Intake Boot.>

6) Remove the throttle body. (non-turbo model) <Ref. to FU(H4SO)-15, REMOVAL, Throttle Body.>

7) Remove the bolt and disconnect the engine harness connector. (non-turbo model)

8) Remove the engine harness connector from the engine hanger rear. (non-turbo model)

9) Remove the engine hanger rear. (non-turbo model)

10) Install the engine hanger rear for turbo model. (non-turbo model)

Part No. 10004AA180 Engine hanger rear

Tightening torque: 16 N*m (1.6 kgf-m, 11.8 ft-lb)

11) Lift up the vehicle.

12) Remove the center exhaust pipe and rear exhaust pipe. (non-turbo model) <Ref. to EX(H4SO)-8, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4SO)-9, REMOVAL, Rear Exhaust Pipe.>

13) Remove the center exhaust pipe (rear) and rear exhaust pipe. (turbo model) <Ref. to EX(H4DOTC)-12, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-15, REMOVAL, Rear Exhaust Pipe.>

14) Remove the heat shield cover.

15) Lower the vehicle.

16) Remove the nuts from left and right transmission mounting brackets.

17) Set the ST1 and ST2 to vehicle.

ST1 99099AJ000 ENGINE HANGER
ST2 99099AJ010 CHAIN BALANCER

CAUTION:

• Set so that the chain sling does not hit the engine parts.
• Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.

18) Remove the stopper rod.

19) Lift the engine slightly and remove the engine mounting bolts.

20) Remove the engine mounting nut and bolt to remove the engine mounting.

21) Temporarily attach ST by using two bolts.

ST 41099AJ000 SPECIAL TOOL H4

22) Lift up the engine unit high enough to install the bolt and nut to vehicle.

CAUTION: Do not lift up higher than enough level to install the ST to avoid damage to the hoses and pipes inside the engine room.

NOTE:

• If it is difficult to pull out the stud bolt from transmission mounting bracket, slightly shake the engine unit while lifting up.

23) Tighten the mounting bolts on the engine side.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

24) Rotate the handle of the ST (ENGINE HANGER) to loosen the sling chain.

25) Lift up the vehicle.

26) Set the transmission jack to the transmission.

27) Remove the clamp cable and take out the MT gear select cable from the clamp.

1. Clamp cable

28) Remove the mounting bolts from the front crossmember and rear crossmember, and lower the transmission.

CAUTION: When lowering the transmission, make sure that the transmission jack does not come off from the transmission.

29) Insert a spanner between the selector lever COMPL and the MT gear select cable and remove the MT gear select cable by raising the handle.

NOTE:

• Use a spanner with 11 to 13 in size.
• The thickness of the spanner must not exceed 6 mm (0.2 in).

1. MT gear select cable
2. Spanner
3. Forward

30) Remove the MT gear select cable and select bracket as a single unit from the transmission body.

1. Select bracket
2. MT gear select cable

31) Remove the plate cable assembly.

32) Disconnect the MT gear select cable.

CAUTION: Be careful not to deform the cable inner.

NOTE: Push the MT gear select cable in the direction of arrow, and remove it.

1. MT gear select cable

33) Remove the clamp which holds the MT gear select cable.

1. Clamp
2. MT gear select cable

34) Pull out the MT gear select cable from the cover cable assembly.

CAUTION: Do not bend the MT gear select cable sharply.

B: INSTALLATION

CAUTION:

• Always use new MT gear select cable if the cable is removed from selector lever COMPL of transmission side.
• Do not bend the MT gear select cable sharply.
• Do not twist the inner cable excessively.

1) Remove the MT gear select cable from the select bracket.

CAUTION: Check for assembling position before removing the MT gear select cable from the select bracket.

1. MT gear select cable
2. Select bracket

2) Set to the new MT gear select cable to the select bracket and secure it with the clamp.

CAUTION: Be careful not to mistake the MT gear select cable installing direction.

1. MT gear select cable
2. Select bracket
3. Clamp

3) Install the MT gear select cable and select bracket as a single unit to the transmission body.

Tightening torque: 18 N*m (1.8 kgf-m, 13.3 ft-lb)

1. Select bracket
2. MT gear select cable

4) Install the MT gear select cable to the select lever COMPL.

1. Selector lever COMPL
2. MT gear select cable

5) Measure the exposed length (a) of MT gear select cable. If out of specification, adjust the MT gear select cable. <Ref. to CS-95, ADJUSTMENT, MT Gear Select Cable.>

Exposed length (a) of MT gear select cable: Specification: 11 mm (0.4 in)

6) Connect the MT gear select cable.

7) Install the plate cable assembly.

Tightening torque: 7.5 N*m (0.8 kgf-m, 5.5 ft-lb)

8) Insert the MT gear select cable into clamp cable, and install to the transmission.

Tightening torque: 18 N*m (1.8 kgf-m, 13.3 ft-lb)

1. Clamp cable

9) Raise the transmission jack, install the front crossmember and rear crossmember.

Tightening torque:
T1: 75 N*m (7.6 kgf-m, 55.3 ft-lb)
T2: 140 N*m (14.3 kgf-m, 103.3 ft-lb)

10) Rotate the handle of ST (ENGINE HANGER) to apply tension to the sling chain.

11) Take out the transmission jack.

12) Install the heat shield cover.

Tightening torque: 18 N*m (1.8 kgf-m, 13.3 ft-lb)

13) Install the center exhaust pipe and rear exhaust pipe. (non-turbo model) <Ref. to EX(H4SO)-8, INSTALLATION, Center Exhaust Pipe.> <Ref. to EX(H4SO)-9, INSTALLATION, Rear Exhaust Pipe.>

14) Install the center exhaust pipe (rear) and rear exhaust pipe. (turbo model) <Ref. to EX(H4DOTC)-13, INSTALLATION, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-15, INSTALLATION, Rear Exhaust Pipe.>

15) Lower the vehicle.

16) Rotate the handle of ST (ENGINE HANGER) to lift up the engine slightly.

17) Remove the bolts from ST (SPECIAL TOOL H4).

18) Remove the bolt and nut to remove ST (SPECIAL TOOL H4).

19) Temporarily attach the front engine mounting with bolts.

20) Install the bolt and nut to the front engine mounting.

21) Tighten the bolts and nuts of front engine mounting.

Tightening torque:
T1: 25 N*m (2.5 kgf-m, 18.4 ft-lb)
T2: 45 N*m (4.6 kgf-m, 33.2 ft-lb)

22) Install the stopper rod.

Tightening torque: 36 N*m (3.7 kgf-m, 26.6 ft-lb)

23) Attach the nuts to the left and right transmission mounting brackets.

Tightening torque: 45 N*m (4.6 kgf-m, 33.2 ft-lb)

24) Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model.

(non-turbo model)

Tightening torque:
T1: 16 N*m (1.6 kgf-m, 11.8 ft-lb)
T2: 19 N*m (1.9 kgf-m, 14.0 ft-lb)

25) Install the throttle body. (non-turbo model) <Ref. to FU(H4SO)-15, INSTALLATION, Throttle Body.>

26) Install the engine harness connectors to the engine hanger rear. (non-turbo model)

27) Connect the engine harness connectors, and install harness bracket to the engine hanger rear. (non-turbo model) Tightening torque: 7.5 N*m (0.8 kgf-m, 5.5 ft-lb)

28) Install the air intake boot assembly. (non-turbo model) <Ref. to IN(H4SO)-8, INSTALLATION, Air Intake Boot.>

29) Install the intercooler stay and the intercooler. (turbo model) <Ref. to IN(H4DOTC)-18, INSTALLATION, Intercooler.>

30) Attach the grille bracket.

31) Install the air intake duct.

• Non-turbo model <Ref. to IN(H4SO)-9, INSTALLATION, Air Intake Duct.>
• Turbo model <Ref. to IN(H4DOTC)-12, INSTALLATION, Air Intake Duct.>

32) Install the collector cover. (turbo model) 33) Connect the battery ground terminal.

34) Make sure the gears can be shifted accurately into each gear.

C: INSPECTION

1) Check that exposed length (a) of MT gear select cable is within specification.

Exposed length (a) of MT gear select cable: Specification: 11 mm (0.4 in)

2) If it is not within the specification, perform the adjustment. <Ref. to CS-95, ADJUSTMENT, MT Gear Select Cable.>

D: ADJUSTMENT

NOTE: Two person are required to perform the MT gear select cable adjustment. (Only the step 7) requires two workers.)

1) Shift the select lever to the 6th.

2) Remove the plate cable assembly.

3) Disconnect the MT gear select cable.

NOTE: Push the MT gear select cable in the direction of arrow, and remove it.

1. MT gear select cable

4) Measure the exposed length (a) of MT gear select cable.

5) With the slider (green) moved in the direction of arrow, release the lock piece (pink) using a flat tip screwdriver or equivalent tool.

CAUTION: Lock piece is easily damaged for the resin. If the lock piece is damaged, replace the MT gear select cable with a new one.

NOTE: Rotate the MT gear select cable to 180 degrees, slide the slider in the direction of the arrow and push the claw of lock piece.

1. Slider
2. Lock piece
3. Claw
4. Flat tip screwdriver

6) Connect the MT gear select cable to the select lever, with the lock piece released.

1. Lock piece
2. Select lever
3. MT gear select cable

7) Move the select lever to the Rev side, hold the exposed length (a) of MT gear select cable 11 mm (0.4 in) and then push the lock piece.

NOTE: While pulling up the gear shift lever assembly slider, operate the lever to the Rev side.

1. Exposed length 11 mm (0.4 in)

1. Lock piece
2. Select lever
3. MT gear select cable

8) Shift the 5th ←→ 6th and Rev, check whether it is caught.

9) If no fault is found in the shift and select operation, restore the vehicle.

10) If the shift operation is not smooth, readjust the exposed length (a) of the MT gear select cable referring to the figure below.

1. Exposed length of MT gear select cable

1. Extend direction of exposed length of MT gear select cable
2. Shorten direction of exposed length of MT gear select cable
3. Specification of exposed length (a)

• If 5th or 6th gear cannot be selected when cable is pressed to reverse lock bracket: → Extend the exposed length (a) of MT gear select cable.
• If select lever does not move along the cranking line when it is operated from 4th to 5th gear: → Shorten the exposed length (a) of MT gear select cable.

NOTE: If it cannot adjust, replace the MT gear select cable.

General Diagnostic Table

A: INSPECTION

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