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All the connections were perfect. I checked and double checked them everytime I pulled them as that would have been an easy fix. What I'm wondering now is how would the gap have changed or if it didn't why did they work before since changing the gap fixed the problem?
I feel that on the install you have had a plug not seat maybe. There is no way that the gap caused that. Big mystery!

On a second note. Whats wrong with putting antiseize on plug threads? If you have antiseize on the thread then you dont have to worry bout them breaking and dont have to use cleaner to get them out! And a lil antiseize goes a long ways. Your supposed to use antiseize on any aluminum threads or studs especially when heat and water is involved with it! I have used it on the threads and never had a problem and have never used any cleaner. Never had a miss or any fouled plugs and I check and change them often with N2O!
 

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you must be one of the lucky 08 owners that got the new style plug. Please LOOK at the tsb posted in this thread. It will explain why we don't use anti-seize on the threads and do use anti-seize on the lower sleeve/body.
Yes i have the 08 but my friend has the 05 and Ive never had a problem with his either! I seen the tsb posted but same issue remains, with antiseize on the threads it doesnt SEIZE up therefore they dont break!
 

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The reason they want you to put the never seize on the barrel section is because that's where carbon builds up and seizes the barrel section to the cylinder casting. It has nothing at all to do with the threads.

I always use never seize on the threaded section too because it's VERY COMMON for steel threads to gall in aluminum castings causing the threads to be destroyed in the aluminum. This problem is completely unrelated to the common problem of the barrel section of the plug seizing to the cylinder with carbon.
Cool!
 
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