I was just doing a 2nd gen coilpack installation, and when I went to remove the leading coil wire from the dizzy - oh no it's stuck?! oh, just a little bit. the rubber dust cap seems to have melted on the inside slightly, thus adhering it to the terminal. I ended up pulling the wire out of that as i pulled on it, then removing the cap.

I'm positive the wire was pressed as far down in the socket as it could go - is there some other reason that it would get that hot? the coil wires themselves and the dizzy don't ever appear to be hot. i am running MSD blaster coils with NGK wires. if that means anything.

 

sometimes they just stick. i have a set of factory wires (yazaki's NOT NGK!) and they just will not come off the distributor cap!

nothing to worry about at all

 

The fact that the boot was melted leads me to believe your dizzy cap has an issue
and the spark was leaking out past the boot and caused the boot to melt. Make
sure you dizzy cap is still good. Run it at night and see if theres any sparks.

 

there's no sparks, i ran it for a few and put my hand on it for heat, i investigated all contacts and it's good. there's always the chance it just wasn't pushed in all the way.... but i was pretty positive it was. i checked both coil wires to make sure one didn't have a larger metal piece on it as well. i think this was possibly just some sort of freak incident.

 

Are the contact in the cap and the terminals onteh wires two different types of metals?

You could be getting galvanic action from contact between dissimilar metals, which will raise resistance and cause heating, as well as making things stick.

 

I wouldn't think that would cause a difference :O but i guess i could take a look.