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If a spark plug wire breaks at the end, or if it fails a resistance check and the fault is found near an end, it's cheap, easy, & quick to repair rather than replace it. Carefully remove the separated terminal from the spark plug and clean out any remaining wire fragments.
Use a common digital multimeter to test each wire's resistance (Ford specifies 7KOhm/ft) from the plug terminal (inside the boot) to the cap terminal (inside the distributor cap).
See also:
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Forcefully push the wire farther into the boot. It may be necessary to twist or pull it first if the boot is adhered to the wire, but try not to fully remove it. Soapy water will also help the wire slide through the boot, but don't use oils. If the boot is glued, slide a fine straight probe between the wire & boot, and roll it so it breaks the glue all the way around.
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Once the wire extends from the plug end of the boot a few inches, open the clamp section of the terminal to fit over the wire.
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Carefully remove the outer insulation from the end of the plug wire. Don't cut any more than necessary to get a good end on the insulation for the clamp to grab. Also, don't nick the core conductor, which must extend ~3/8" past the insulation. This is a little too much, but the insulation was torn. Cut off the excess conductor before proceeding.
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Fold the conductor over the end of the insulation and insert it into the clamp end of the terminal so it presses into the bottom of the channel.
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Fold the conductor over the end of the insulation and insert it into the clamp end of the terminal so it presses into the bottom of the channel.
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Bending each side a little at a time, close the clamp ends into the wire insulation as tightly as possible without cutting the insulation.
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VERY slowly, pull the boot back down the wire toward the terminal.
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The wire will move more easily when the terminal goes through the bend (where it should stop), so work very slowly.
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The terminal will lie flat inside the boot when it reaches the proper position. Before reinstalling the wire, retest its resistance (Ford specifies 7KOhm/ft) and apply silicone grease (Sil-Glyde, etc.) to the lip of the boot (NOT to the metal terminal inside).
See also:
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Spark Plug Wire Repair
