Ok,

Here are the plugs. Don't know how old they are since I picked up the car in October I've only put about 4,000 miles on them. Mostly city driving with an occasional freeway jaunt [ 1 1/2 hr max]

Plugs 1,2 & 3 look like they are burning the same...#4 tip looks different....

#1 has a special problem...a big problem...look at the threads...brown...
well I don't know why except that somebody [not me] cross threaded that plug and the new NKG won't even go in half way...the threads in the head are clean about 1/2 way in, but the lower 1/2 are brown...

I noticed something felt funny when I was backing it out , it didn't feel like #4,3,2...you know, crack it loose and spin it out with fingertips...

Why me?.......

The inside out thread chaser suggested by Kerry worked like a charm....I now have 4 happily seated spark plugs.... :-)
Tahnks!
John
--
89 245DL M47 300K+mi no rust

Try this tool:

http://www.kd-tools.com/3545.htm

It chases the thread fron the inside -> OUT!

I've wanted to try it out for awhile, but can't justify the cost without a need... I have a thing for tools!

WOW, thanks....that's the right tool for the job!

$80 list....$40 discount

For $20 discount I can get the KD rethread/insert kit [iPd sells it for $40]....

wonder which way is the better way to go?

hmmmmm

My own #1 plug is a real pain in the ass to get in and out and I swore it was cross threaded. But other than being a tight fit, it doesn't seem to be cross threaded. As for the brown - well, all four of my girlfriend's '05 jetta's plugs had brown threads when I changed them the other day. No indication that anything is amiss...

Good luck, hope it isn't cross threaded, and maybe someone else can help more.
--
'93 244: 'A' cam 4 deg. advanced, 25/22 sways, custom heim endlinks, poly bushings, and a lot more styling customization than I care to recount.

Get a spark plug thread chaser and run it in and out a few times. Use a little grease on it, of course. Grease is better than oil for this because any debris will stick better to the grease.
--
john

IF you screw the old plug back in with your fingers do you get it to go all the way home? If no, chase the threads with a axle grease covered tap made for the job, Take a clean rag and catch shavings or cuttings as you take the tap out. You do not want to have any fall in.

Take a really strong vacuum cleaner and (wait for it), duct tape that sucker to a section of hose that just fits down in the hole.

Suck that sucker out like there is no tomorrow.

Apply a liberal coat of nickel coat to the threads and gently run in the new plug.

You should be good to go.

Good Luck and double check that gap before you screw them in all the way.

Regards,

Paul

"IF you screw the old plug back in with your fingers do you get it to go all the way home?"

NO, it wasn't all the way in, and won't go all the way in either.... :-(

You can see in my photo that the crush ring was never compressed. So there never was a really good seal there. I guess that's why the threads on that plug are brown.

I'll try the thread chaser route, but I dunno if that's gonna work...right now the bottom 1/2 of the hole has the correct thread [albeit caked w/ brown deposits] and the top 1/2 of the hole has the cross-threaded [ or misaligned ] thread...I don't see how the thread chaser will transition from following the misaligned thread section into correct thread without doing further damage...

You can chase the threads with a axle grease covered tap made for the job, Take a clean rag and catch shavings or cuttings as you take the tap out and take your time. You do not want to have any junk fall in.

Take a really strong vacuum cleaner and (wait for it), duct tape that sucker to a section of hose that just fits down in the hole. Start with the threads and work your way in. Suck that sucker out like there is no tomorrow.

Apply a liberal coat of nickel coat to the threads and gently run in the new plug.

You should be good to go.

Good Luck and double check that gap before you screw them in all the way.

Regards,

Paul