Shocking Spark Plug Wire Trouble

[sandy]

Spent the last few days (well a few hours, still sad) trying to get a spark plug wire on the #7 Cylinder on the Tiger. Not much room, non-cooperative plug boot, and finally a broken spark plug connector. Not sure why so hard but ruined a spark plug wire as I broke the contact in half after trying to get it on the plug. Bottom line is that the 135 degree plug wire will not work on this cylinder (possibly others). Part of the problem is the thick header flange and how close the bolt is over the plug which prevents easy
positioning of the wire boot around it.

So off to Summit for more wires. Snapping the wire on the plug is easy if you can get you hand in and apply pressure at the right angle and strength. Can't quite do that, tried to use a small piece of metal to try to pop it on, all that did was scratch up the paint on the support brace

Going to try a straight boot for this one and see how it goes. Also ordered some spare metal clips for the spark plug to see if I can repair the one that is broken or get broken. The wires are F'n expensive these days

Laying out the wires, 1 out of 8 connected to a plug. Driver size is difficult to get them on the plugs.

Box number 2 cracked open (steeling from the Mustang Project). Taylor 409 10.4mm wires are nice!

After trying to get #7 wire on, this was the results of trying. Going to try a straight plug boot on the problematic ones.

The driver side has really limited access to getting your hand in the rear 2 cylinders due to the steering shaft. I should really just take it out and put the wires on, but not good to need to do that so going to try a straight (180 degree) boot.

 

[HolyCat]

Sandy,

Sorry to hear about your difficulties. This is probably obvious, but did you check the new spark plug connector to make sure it had not been crushed and would fit over the tip of a spark plug?

Good luck with the new connector of a different shape.

Thanks!
David

 

[sandy]

Sandy,

Sorry to hear about your difficulties. This is probably obvious, but did you check the new spark plug connector to make sure it had not been crushed and would fit over the tip of a spark plug?

Good luck with the new connector of a different shape.

Thanks!
David

Yeah, I did the put a plug in and out drill a bunch of times to possibly loosen it up a bit. Didn't help, but did reaffirm that plug wires will not ever vibrate off .

 

[Agent 861]

The issue I have is that they vibrate off particularly Number 7 and Number 3 . Number 3 is not to bad to get back on but Number 7 is a right #$%#. Unfortunately I have very big hands ! I've tried tightening up the clips but still a persistent problem

 

[sandy]

The issue I have is that they vibrate off particularly Number 7 and Number 3 . Number 3 is not to bad to get back on but Number 7 is a right #$%#. Unfortunately I have very big hands ! I've tried tightening up the clips but still a persistent problem

That is one thing these will not come off easily, or go on for that matter

 

[hottigr]

The issue I have is that they vibrate off particularly Number 7 and Number 3 . Number 3 is not to bad to get back on but Number 7 is a right #$%#. Unfortunately I have very big hands ! I've tried tightening up the clips but still a persistent problem

They might not be vibrating off- mine have come loose under hard acceleration when the engine torques hard!

 

[Agent 861]

They might not be vibrating off- mine have come loose under hard acceleration when the engine torques hard!

Maybe -but no hard acceleration would be a bad solution to the problem!!! I'll just keep putting them back on . Some one once told me that they popped off as the head expanded the air in the boot -Sounds unlikely to me

 

[hottigr]

It's cumulative- not a one-time acceleration problem- I can usually catch it before it comes completely off because it will start idling a bit rough.

 

[sandy]

All wires and plugs in and good to start routing to the distributor. Found a replacement part for the clips from Taylor, figured I would give it one last try with the 135 degree set. Seemed to do the job! Got all the plugs in without too much trouble (well the #8 plug had to be put in prior to header install).

All header tubes installed as well. Moving along!

The broken plug clip

The same clips used in the 8mm wires, had to get the boots, but what can you do.

It's ON!

Good to go on this side, plugs installed, and all header tubes on

Little different angle, it's tight

Passenger side, all plugs, tubes and wires installed!

Now to route and connect to the 'Dizzy'