Topic: Spark Plug Wires Popping Off Plugs
in Forum: C3 Engines
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Short story, had a shop put a new exhaust system on my 80.....new wire set was needed to clear the manifolds coming off the block.
Shop ordered in and built the wire set (not a hard thing to do really) and I got the car back about 2.5 months ago.
Driven the car about 800 miles since then.
Yesterday I was on the freeway and the car started running really rough. Got off on next exit and looked under the car...nonfluids leaking but sure as sh!+ there was a spark plug wire dangling.
Right side (facing forward) closest to the firewall had popped off.
Awkward position on a hot engine...bought a set of gloves and adjustable pliers insode the gas station and got the plug wire reattached.
Drove 35 yards and the problem re-emerged....popped the hood and left side second from firewal was hanging off the plug....that ready me was partially melted as it fell into onto an exhaust pipe. I was able to reattach it and it works.
Drove another 8 miles and sure as sh!+ right side 2nd from firewall pops off the plug!
Popped it back in and have have driven it about 25 miles since then with no issues.
Accepting comments....:)
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Either they were not properly installed, or the wires are no good.

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Duncanville, TX - USA
Joined: 11/8/2003
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Vette(s): #1-1974 L-48 4spd Cp Med Red Metallic/Black deluxe int w/AC/tilt/tele./p/w-p/b/
Am-Fm/map light National/Regional/Chapter NCRS "Top Flight"
#2-1985 Bright Red/Carmine Cp.L-98/auto
Member: NCRS, NCRS Texas, Corvette Legends of Texas
Won't cause any major damage if they fall off, other than melting the wires, or possibly firing up a fuel leak, but as you know, it ain't gunna run very well!
If you have gone thru and verified ALL of them are pushed all the way down onto the plugs, and you felt the "click" of the metal terminal, then they should not fall off again. Just the tension of the boots themselves should hold the wires on, even if the terminals are a little loose. Make sure you have the correct size boots(and terminals) for the plugs....there are different sizes of boots, since some older plugs have larger diameter porcelain than the later ones.

If you have gone thru and verified ALL of them are pushed all the way down onto the plugs, and you felt the "click" of the metal terminal, then they should not fall off again. Just the tension of the boots themselves should hold the wires on, even if the terminals are a little loose. Make sure you have the correct size boots(and terminals) for the plugs....there are different sizes of boots, since some older plugs have larger diameter porcelain than the later ones.

Joel Adams
C3VR Lifetime Member #56
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Talked with the shop via phone and told them the circumstances (falling off at freeway speeds).
the guys first question was do you have headers? The answer to that is yes, and the question tells me he's familiar with this problem because the headers must be vibrating too much and shaking the wires loose.

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#2-1985 Bright Red/Carmine Cp.L-98/auto
Member: NCRS, NCRS Texas, Corvette Legends of Texas
EDeBella said: Short story, had a shop put a new exhaust system on my 80.....new wire set was needed to clear the manifolds coming off the block.
Shop ordered in and built the wire set
Hmmmm....they must have a really bad memory if they don't remember installing the headers themselves....

Never heard of a tube steel header vibrating enough to blow the wires off the plugs. I'll have to store that one in my "Are you f-ing kiddin me?!" file....

My suspicion is that the wire terminals are not right, or not properly seated.
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If they are snapping on correctly and the boots are the right size, try adding a little dab of silicone grease to the inside lip of the boot. It may allow the boots to slide a little further down and remove some resistance if the boots are dry and pushing against the porcelain.
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