Hey guys,

I need some help. My husband owns this Ford and just replaced the spark plugs and wires. But now everytime he drives it, this one spark plug keeps popping off. Why is this happening? And how do we fix it?

I really love this Ford and want to make it nice for him.

Any help would be appreciated.

Erin

 

do you mean the plug wire comes off?

 

If the plug is popping out of the head, someone stripped the spark plug hole out and it will need to be re-drilled and have a helicoil put in place. You have to remove the head from the motor for this, as metal shavings in the cylinder will ruin the engine.

It's a lot of work to do yourself, and a shop would charge quite a bit for this kind of work to be done, too. I would guess about $800 to $1000, mostly labor involved in getting the head off and re-installing it.

 

Yes the plug wire comes off. We replaced them last year and never had this problem. Although this year, we had gotten the spark plugs and wires but they were the wrong ones, so we went back and got the right ones. So we have put them on and off.

Thanks for your help!

 

If you are still having problems with the wires coming off, you could squeeze the metal ring that snaps onto the plug. If you look inside the boot, you will see it. When you remove and install a couple times, they get loose. Careful not to damage the boot when doing this as it may cause arching. Some auto parts sell individual wires and you could replace the offending wire completely.
Next time use Motorcraft wires, you won't have a problem.

 

It also means you probably bought some generic plug wires. The rubber boot that covers the plug doesn't fit the plug real well and squeezes itself off. Crimp the metal ring like alz recommends and if that doesn't work spend a few more bucks and get a set of wires that fit better. If you go to a parts store and ask for plug wires they'll usually have 2-3 options to choose from each with a different price. The more costly wires are usually a little thicker (which is good), the lengths of each wire are closer to stock, and the fit on the dust boot on top is usually better too.

So if it keeps doing it and crimping the metal ring doesn't help take them back, ask for a refund and get the better set.

 

what brand wires? from where?

i would advise sticking to motorcraft.

 

Thanks for your responses.

My husband said he did get the more costly wires. But now they are starting to burn. What does this mean?

Erin

 

If they are laying on hot exhaust pieces, they will be damaged. They need to be clear of all exhaust manifolds. The less expensive wires(non-Motorcraft) may not have the correct boot angle going to the plug(90* or 45*).

 

do the end of the sparkplugs just have threads or is the "nipple" threaded on to them?

 

it means you need to buy new wires.

more attention to the routing of the wires when they are installed is a must.

more expensive wires do not mean good wires.

what brand?

maybe it would help if he posted directly.

 

Could be a sign the base timing is off, "late ignition" causing the air/fuel mix to burn in the exhaust manifolds causing them to glow red hot, burning up the wires. The rubber boots will be almost brittle or show many small hairline like cracks when slightly bent over to one side when holding them in hand.

If the heat shields for the wires have rotted away and are gone tell em to use wires build to run with headers, use good quality wires. And make sure the base timing is set to 10deg BTDC (before top dead center) minimum. Probably run better bumped up to 12deg.

He will need a timing light to set the timing, a vacuum gauge is the next best thing. It will show timing but is not as exact as a light.

 

Depends on where they're burning. If the rubber insulation is burning then yeah, what they said above. If the metal ring that alz recommended you have him tighten is loose, the metal will arc and burn. I know this because I had this happen. My truck ran bad and when I removed the wires, the terminals were all burnt up from arcing.