Chevy Trucks 5.3L

[FiendFX]

Is there a trick to remove the spark plug wires without breaking them?

 

[GTA Matt]

Long hose pliers as close to the plug as you can get them around the heat shield boot. Brace it against an exhaust manifold bolt for leverage and pry them out. However, if they have been on for a long time, there is no guarantee they won't break, this just minimizes the chances.

 

[Zrexxer]

I just did my 5.3, and they're a challenge. But I managed to salvage all 8 of them. Some of them are a LOT easier to access than others. First thing is take the connector off the coil pack first, that's easier to do and keeps you from tearing it up trying to get the plug end off.

The metal shield around the plug end is smaller at the engine end, so it can be used to pull the boots off without tearing them. If you can get a set of pliers like the ones below onto the groove in the metal shield, it helps a lot. Some I was able to twist until it broke the grip on the plug insulator. The hardest one to get to - the #8 plug next to the firewall on the passenger side - actually came off the easiest for me.

If I had it to do over, I wouldn't have spent all that time dicking with them. A new set of AC Delco wires is like $32. I'd have just ordered a new set of wires and not worried about ripping the old ones.

 

[FiendFX]

I just did my 5.3, and they're a challenge. But I managed to salvage all 8 of them. Some of them are a LOT easier to access than others. First thing is take the connector off the coil pack first, that's easier to do and keeps you from tearing it up trying to get the plug end off.

The metal shield around the plug end is smaller at the engine end, so it can be used to pull the boots off without tearing them. If you can get a set of pliers like the ones below onto the groove in the metal shield, it helps a lot. Some I was able to twist until it broke the grip on the plug insulator. The hardest one to get to - the #8 plug next to the firewall on the passenger side - actually came off the easiest for me.

If I had it to do over, I wouldn't have spent all that time dicking with them. A new set of AC Delco wires is like $32. I'd have just ordered a new set of wires and not worried about ripping the old ones.

That's the plier I was using. The problem is not the insulator damage. It's the electrode that falls out. That's how bad it was.

 

[Sam'sAutoParts]

when I did the plugs on my 6.0 (2004 Chevy Express) I just went ahead and bought new wires, saved myself a lot of head aches, although the van is a little easier to get at the rear plugs with the engine cover off.

 

[Ign]

X3 on new wires

 

[ChrisLS8]

Yep, just did the plugs and wires on a friends Tahoe, Used hose clamp pliers on the majority of them. The ones in the back I had to pry out.

Just buy new ones before you start on them.

 

[rmmiller]

If they want to come apart they have fulfilled their life expectancy.

 

[fm2176]

Get a GMC and you won't have that problem, damned cheap Chevys.

Seriously, though, another vote for new wires here. I replaced mine with Super Conductors a few years and 100,000 miles ago. Those 5.3 GMT 800 trucks can be extremely reliable, in my biased opinion. I know a guy who drives a '99 Silverado with over 300k, and my '06 Sierra is pushing 190k with nothing more than routine maintenance and front hub assemblies.

 

[shockwave]

Best you can do is twist and pull at heat cover but most of the time at least 1 wire breaks I usually always put new wires on

For this reason I have a used set for customers that font want to change wires incase one breaks on me

 

[devoncoolman]

Hose pliers are usually the best. But its likely to break atleast one. I always replace the wires too.

 

[arz71]

Get a GMC and you won't have that problem, damned cheap Chevys.

Seriously, though, another vote for new wires here. I replaced mine with Super Conductors a few years and 100,000 miles ago. Those 5.3 GMT 800 trucks can be extremely reliable, in my biased opinion. I know a guy who drives a '99 Silverado with over 300k, and my '06 Sierra is pushing 190k with nothing more than routine maintenance and front hub assemblies.

Have had several 5.3L's and they are tough, regular maintenance and have one now with 250,000 on it. Another one preacher has well over 300,000 miles on it.

Ditto on the A/C Delco wires, I always go back OEM on parts they work correctly and fit.

The plug wires if still good one can twist the end a bit and pull it free they can be a bear tho. At that price tho, it is better to replace them.

 

[1949 caddyman]

As a former tune up tech at a Chevy store often the wire is damaged when removed. I would ohm the wires before reinstalling them & found some bad even though they came off in one piece. I would replace them if I was you.

 

[GCncsuHD]

It's very common, might as well just yank them off and replace them anytime you have them off, they are relatively cheap. Besides, the OEM Iridium plugs and wires are 100K mi pieces, it's not like you need to do a tuneup that often.

 

[cmandp]

I had the same problem as the op when I did my spark plugs on my 2.2L S10. I wasnt going to do the wires that day because I knew if was a pain to fish them through the engine bay to the coilpack.

 

[JKennedy]

I have an 07' 5.3L and I just did this last month. I tried to find a good way to do it and it's almost like it was a hit or miss thing... I saved all wires but if I had them on hand I would've replaced them all anyway. I tried a twist while pulling technique and it worked on 5 out of 8 boots but the others ( the far back ones) gave me issues.

I didn't have any plug pliers, but I did use channellocks on the rear plugs to help me out.

It's not comfortable. It's not fun.
Let's just say I had a beer or three after

 

[stage20]

do yourself a favor and buy msd replacement wires. they are 30 bucks cheaper than factory wires and will hold up to the heat overtime. ive never pulled a factory wire off a 4.8 5.3 or 6.0 that didnt break or i was scared to reuse after pulling off.

 

[chris142]

No problem getting them of my wife's Tahoe. Just twist and pull.

 

[Petey156]

Put plug grease on new wires and go from there

 

[arz71]

As a former tune up tech at a Chevy store often the wire is damaged when removed. I would ohm the wires before reinstalling them & found some bad even though they came off in one piece. I would replace them if I was you.

Good advice!