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Problem fixed! Sure enough, the plug had completely galled about 1/16" on the first thread. I am using the Beru plugs on my 01 boxster, as that is what Pelican parts claims is OEM. However, the old plugs I took out were indeed Bosch, so I guess Pelican is incorrect. The Beru plugs have stainless steel threads as opposed to the stronger and less-galling copper or brass threads of the Bosch plugs. The key here is, you need to use Never-Seize on the Beru plugs to make sure that you don't gall the internal threading in the engine, cause then you have a BIG BIG problem like I did today. Also, do not even think about using a wrench to tighten the plugs until the very last turn. The plug must go in by hand, but if for some reason it should not then you have to go to Plan B. The parts guy at Pep Boys walked me through these steps and it ended up working for me. Plan B involves using a spark plug threaded Tap (available at Pep Boys) to clean up the inside threads. The problem with the tap you get at Pep Boys is the fact that the socket needed to drive it in is too large to fit into the first part of the spark plug hole. Instead what I did, is to use the larger-tap on the other side (the tap has two heads, one big and one Boxster-sized) to set itself snugly into one of my larger sized hex-sockets. I know this might destroy the socket, but it is totally worth it, and should now fit into the spark plug hole. Coat the useful side of the tap with some form of thick grease, that will be used to trap metal particles that you scrape off during the tapping process. Don't overdo it on the grease, but get enough in the intermittent grooves to trap the particles there. A lighter layer of the grease on the threads will help lubricate the tapping. Insert the tap into the hole and rotate it slowly counter-clockwise until you feel it set in the first thread, then advance it clockwise as usual. SLOWLY advance and then back out the tap. Do not use too much pressure, even though a small wrench may be needed to help advance the tap through the galled portions. You never have to apply hard pressure and there is never any seizing. If it is seizing you need to back out, clean your tap, regrease, and re-enter. Remove the tap completely very often in order to clean off the grease and metal shaving, then re-apply grease and begin again. By slowly inserting and removing the tap many times you should be able to clear most of the gall and get your plug through. After you have made good progress on the threads, do not try to force the final few threads of the tap through. I believe my tap was slightly longer by about 2-3 threads than what was needed, so don't make a new thread inside your engine! Good luck if this should ever happen to you. -Nicholas
HELP! HELP! HELP! I'm in the middle of replacing my plugs and am currently working on the passenger side front plug (the hard to reach one). I removed the old plug with no problems but when I went to insert the new plug, I can make it in about four turns and then it stops. I'm afraid it may be Galling up in there. What should I do? Should I try some never-seize or do I have a more serious problem on my hands. Any help would be much appreciated. Thank you. -Nichlolas