Can’t remove spark plug leads

[Redmonds944]

Hi guys,
This one’s a little embarrassing to the point I nearly posted anonymously.

I replaced my ignition leads with genuine Bosch leads about 12 months ago and now I just want to check over the plugs.
But, no matter how hard I pull I can’t get the leads off the top of the plugs. I’m pulling the leads up by about 20mm clearing the spark plug cap and can feel them stretching to the point I think their going to tear but the body of the lead remains wedged in the head.
Is there any suggestions of how to get them out and what I should do when replacing the back in?

Thanks in advance Rob

[PSU_Crash]

I always put a little dielectric grease on the inside of the spark plug boot. Helps to keep the connection clean and also keeps the wires from sticking to the plug.
As for getting them out, I get a good grip and pull stright up. It takes a good bit of force to pop them out. Sounds like you have done that though. All of them are stuck? Are you saying the boot is pulling up, but the connection to the plug isn't letting go? Maybe they have welded to the pug? Seems unlikely although not impossible

[Redmonds944]

Hi,
Exactly as you say, the boots are pulling up but as I’ve now found the caps are wedged on top of the plugs.
I have them all off now but I’ve attached a picture of cap number one as it came off. Can I just push it back in or is a new lead needed?

IMG_5683.jpeg (2.6 MiB) Viewed 346 times

[Tom]

Hi,
Exactly as you say, the boots are pulling up but as I’ve now found the caps are wedged on top of the plugs.
I have them all off now but I’ve attached a picture of cap number one as it came off. Can I just push it back in or is a new lead needed?
IMG_5683.jpeg

I'm not sure what we're looking at in that boot? The spark plug itself looks normal, but all that gold connector metal coming out of the boot is throwing me off. Normally the part that clips onto the plug is recessed way up inside the boot -- not popping out the end like that. That boot is supposed to push all the way down inside the spark plug well to create a water tight seal. Do yours? I'm not sure what you mean by 'caps' wedged on the plugs? You should just have spark plugs and spark plug wires. Do you have separate gold colored caps or something? The wires should look like this picture -- note the 'empty' boots, and how far into the well they would need to sit to clip on the plugs. I'm wondering if your connectors got stuck on the plugs while you pulled on the boot, such that the boot slid up the wire -- or, worse, broke off the connector? If the boot just slid (??), the wires might be ok of you can push the boots back down, but I'd also be worried all the pulling compromised the connections inside. Either that, or I'm completely confused about what we're looking at, which is a real possibility.

IMG_0349.jpeg (31.66 KiB) Viewed 327 times

[996C438]

I would check continuity on the plug wire in the pic end to end . It is possible the brass piece stretched so far that it ripped from the internal wire . If you have continuity I say push it back into the boot and use it . If you have a misfire you will know it's probably that wire .

Install with dielectric grease to avoid future issues . Add the grease to all four and on both ends . Good luck

[PSU_Crash]

I'll 3rd just pushing them back in.
I have other vehicles where I've had issues with pulling the guts out of the boot. Using plug boot pliers was the answer there, as well as dielectric grease.
If you're worried about damage, test the wire. Multimeter is a quick way to see. Using an inline spark tester will also let you know if there is a problem. I bet it will be fine.

[spacecad3t]

...Using plug boot pliers was the answer there, as well as dielectric grease.

The 944 was the first car I purchased pliers for, my hands barely fit between the runners to get a good grip on the boots.

[Redmonds944]

Is it possible to but individually Bosch leads?
Number to is now damaged beyond repair.

[PSU_Crash]

Is it possible to but individually Bosch leads?
Number to is now damaged beyond repair.

I can't remember if I threw out the old set when I swapped wires recently. Nothing wrong with them, just winter maintenance. If they're still in the shop I'd be happy to send them your way. Tomorrow evening I'll try to remember to take a look.