Help! Beru spark plug connector to distributor cap broke!

[toddetch]

Installing new spark plug wires this morning. All were really tight going on the distributor cap. The connector to the number one wire broke off. Anything to be done besides getting a new set? I didn’t feel like I was putting much pressure on it...

[toddetch]

uploading pics from mobile doesn't work very well...here's a pic

looks like the joint between the wire and the connector was not that strong

[toddetch]

Also, while I have your attention...I’m unsure where to connect the grounds from the wires to the chassis.

[manbridge 74]

I might have a spare around, what length? Resistors at both ends or one? Maybe take a pic.

[Tony V]

Grounds connect under one of the nuts holding the coil to the fan housing. Inside nut.
I’d try installing a new connector on the existing wire. The ground shielding are all crimped together for each bank. The wires also are installed into the holders before the ends go on. Replacing one wire will leave you with one loose wire. Measure the resistance of an intact cable and the broken one to see if there’s a difference.

[toddetch]

Thanks. What I realized is that the back of the connector where it connects to the wire was threaded like a screw. I think maybe it just hadn’t been connected tot he wire well. I screwed it in and checked the resistance, which was the same as another one of the good wires. It seems to be well connected and seated. Car started and ran well. Now for a test drive.

Thanks Tony for the tip on connecting the ground wires. When I looked closer at the inside of the coil I could see a brown ground wire on that nut.

[john walker's workshop]

Not my favorite wire set. Hard to get onto the cap and a bittch to get them off. Actually broke a cap terminal last time.

[rgofast]

We’ve had nothing but trouble with the new beru sets falling apart at the plug connectors. Very little glue holding them together verses the older ones. We switched to Clewett plug wires as er were not concerned with the stock look

[schoward]

Originally Posted by rgofast

We’ve had nothing but trouble with the new beru sets falling apart at the plug connectors. Very little glue holding them together verses the older ones. We switched to Clewett plug wires as er were not concerned with the stock look

Same experience. 3 wires fell apart in same manner at the cap connector in a matter of DAYS. Sent them back for a refund. Put my circa 2007 Berus back in and all good.

Interesting how the brand new beru set fell apart with the slightest tug or twist, yet my 2007 set stayed rock solid despite me yanking them out like a gorilla.

[WP0ZZZ]

Those Beru connectors are really tight! I’m battling with them at the moment and feel like there must be a trick to connect them. Anyone?

[kevstens]

Assemble using Bosch dielectric grease.

[smadsen]

Beru now prolly made in Brazil.

Install with dielectric grease as stated above, use heavy paperclip to relieve trapped air pocket to get boot to seat properly on cap.

[Superman]

I'm not sure what John is reporting. Perhaps the parts have changed. I have a box of Beru ends, both spark plug and cap. They just screw onto the cable. Easy schmeezy. Nary a problem..

[WP0ZZZ]

Thanks for the tips. Air clearly gets trapped between the boot and the distributor cap so relieving it will be useful. However, even when making sure that air is not getting trapped I'm struggling to insert the connector.

Here are some measurements that I've taken:

- Distributor cap electrical connector: 8.3 mm internal diameter
- Ignition wire connector plastic plug that gets inserted into distributor cap: 7.8 mm external diameter

Looking at that, it looks easy but the problem is that the electrical part of the connector is clearly larger than 9 mm even when pressing it quite hard:



I'm using pliers to make the electrical connector closer to 8.3 mm but can't help thinking that there must be a more delicate way to solve the problem...