It worked just fine on another Onkyo ... but this one, no sound -- power is on, etc. ... and, interestingly, when going through channel select options, "subwoofer' is not an option (although front R and L speakers, surround R and L speakers and center speaker ARE options ...
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It sounds like you're doing everything right. Did you define the sub to the Onkyo (Subwoofer = Yes, page 22)?
Let's prove the sub works. Set its volume about half-way, cutoff= 170Hz. Temporarily connect an RCA cable from its Line Input to one of the Tape Out connectors on the Onkyo and play some FM through it. If it's alive you'll hear the low end of the music.
Don't buy into the hype that there are different pedigrees of RCA (or speaker) cables that will make an audible difference. Save your money.
The surround processing portion of the unit has a problem. In either stereo or direct mode, the digital procesing is bypassed. This could be just the surround processing IC, but that IC may not be available as a separate part. I would suggest that you bring this unit to an authorized Onkyo service center for an estimate.
Also, it could possibly the preout terminal itself that is not working. One way to prove that is by transferring the subwoofer cable from the preout and temporarily transfer it to the tape out section. If it ouputs sound from there, then that means the speaker and the cables are working fine and it's just the preout terminal itself that is not picking up anything. ^_^