nc_growler

So, I just ordered a nice set of replacement Beru wires.

And I just finished removing all of them (without breaking any of those plastic clips - which I count as a success).

I'm now ready to replace the existing wires by following the instructions that came with the Beru wires. Using a probe tool, I have loosened the boot around the distributor connector end of one of the coil wires and allowed some of the "dressing" to drip down the probe into the area where the wire and the connector meet. Now that the boot is completely loosened from the wire itself, I start unscrewing the wire from the distributor connector.. It feels like it is turning so I proceed. After several more twists, the wire comes out.

But... the wire has simply twisted off the connector+screw at the end of the wire. And the screw/connector is now embedded in the boot that goes on the distributor.

First connector and I appear to be in trouble. And I suddenly think to myself "perhaps this set of wires doesn't actually have twist off connectors?"

Anyone else have any experience here? I suspect some needle-nose pliers and some patience may win out, but I'm afraid I'm going to be doing this 15 more times if I don't change my strategy. Open to tons of suggestions for how to do this better. Here are two pictures of the connectors on the spark plug wires I'm taking off the car (one of the twisted off wire/connector issue)

Help!

wpgshark

I've only ever seen the Beru with the threaded ends, the distributor ends are not so I'm suspecting that they are not threaded, are the spark plug adapters Beru? Could have been a Frankestein conversion, beru ends put on the spark plug end of the Bremi wire. If the spark plug adapters are Beru, that is the bulk of the value, the distributor adapters are not that expensive.

nc_growler

Winnipeg Shark - Thanks... That's kind of what I think I've run into here... A non-threaded end set of wires. I'm reaching out to my supplier for some guidance.

harveyf

My distributor cap ends were not threaded. I wound up buying a set of used threaded caps from 928International.

Brian'sIris

I had the same problem when removing the original Beru plugs from my old wires. One of the crimped-on threaded pieces came loose and became stuck inside the plug. What I did was first spray some penetrating lube down there and let it soak. Then I found an M6 bolt long enough to thread into the offending crimped connector (IIRC I tried a few other bolt sizes, but M6 fits best). Once the M6 bolt was threaded in far enough (try and get it in without twisting too hard), I simply unscrewed it and the crimped piece came out along with the bolt.

If you have Beru connectors, then all of the plug wires and distributor wires will (or should, if original) have these threaded ends...at least mine did ('85, 32V).

Don't forget to clean out the penetrating lube afterward, as it could deteriorate the rubber. I use mineral spirits for cleaning since it's compatible with many elastomeric pieces and will evaporate fairly quickly.

Hope this helps!

Cheers,
Brian

Mark Anderson

I thought the distributor cap end was crimped on. Our economy set comes with that installed but the spark plug end has screw on connections.

wpgshark

All of mine had threaded ends, 88 and 89 on both ends.

An easy out is also an effective way of getting a broken male crimp out of the end in which it is stuck.

Brian'sIris

+1 on the Easy Out, if you have the right size. Those spiral-type extractors are usually tapered. Keep in mind, you don't want to use something that will stretch the rubber too much, or risk cutting into the rubber.

Best of luck!

nc_growler

Turns out the set that is in my car was aftermarket and did not have threaded ends on the distributor side.

My supplier has graciously offered to accept the return of a very nice set of BERU wires in exchange for a set of OE wires (plus the difference).

Another case of WYAIT getting the better of me... These aftermarket wires were actually pretty nice still, I was just doing my first ignition tune up and thought I should eliminate potential problems by swapping out the old wires. Live and learn?

Thanks for all the comments.