Auto Repair: How do you remove a stuck spark plug with fused wire?
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I bought new spark plugs to replace in my 02 camaro (v6) and the spark plug wire boots are all jammed or fused or something. We could only get one spark plug wire off the spark plug but the rest won't budge. We've tried liquid wrench, warming up the car, pliers.. everything. Any tips on how to loosen up the spark plug wire?
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Answer:
You should probably not use liquid wrench because you don't want penetrating oil to get into your engine or cylinder head. It can seep past the spark plug threads, the valve cover gasket (most likely), or if it is pooled up there it can of course drip in once you finally remove the spark plug. You should be able to remove them with pliers, especially if you have spark plug boot pliers. If that doesn't work for you, cut the spark plug wire an inch after the boot and then use a utility knife to cut the rubber boot off. You should be left with a relatively thin wire that you can fit the spark plug socket over, or you can remove the "fused" metal clip from the back of the spark plug with pliers at that point. If you are not sure what the part that gets stuck looks like, you should look at your new wires, or the one old one you were able to remove. Push the wire through the boot to expose the metal clip, or just cut the boot off so you know what you are dealing with. You should be changing your spark plug wires with the spark plugs, especially if they are stuck on there. So don't worry about being rough with the pliers. If you don't mind messing them up there is almost no possible way they won't just come off with pliers. Make sure you use a dab of dielectric grease inside the new boots if they don't already come with some in there to make sure this doesn't happen again.
Ramsey Mesyef at Quora Visit the source
Other answers
You can cut the plug wire off and attempt to take the plug out with a small chunk of the wire still attached. If this is occurring be sure to replace the plug wires with the plugs. If you still can't get the plug out you may need to have a mechanic drill the old plugs out of the head. It is possible to do this, but not all mechanics will be willing to do this for you because there's a good chance that metal shavings will end up in your combustion chamber. The mechanic should not have to remove the heads for this. Find a mechanic on Google Places or Yelp with good ratings near you. Regular maintenance would most likely have negated this situation, an ounce of prevention is worth a pound of cure!
Nathan Kaemingk
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