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WARNING About CHAMPION Spark Plugs

Jun 08 '01

The Bottom Line CHAMPION spark plugs reportedly have an abnormally-high rate of seizing in aluminum engine heads. AVOID using these plugs if your car has an aluminum head.

We just paid $600 to have unnecessary repairs done on one of our cars. Why? Because two spark plugs (two out of four) seized in the engine head, and couldn't be removed (in fact, one broke off trying to remove it). The engine had to be dismantled, and the head sent to a machine shop to have the seized plugs drilled out, and the holes re-tapped.

Why did this happen ? Well, the spark plugs were properly installed and not over-tightened, and anti-seize compound was applied before installation. The plugs installed were CHAMPION CopperPlus (Federal Mogul Corp).

I checked with a number of professional mechanics, and some hot-shot car enthusiasts/hobbyists, and they all said the same thing: "Never, NEVER, EVER install CHAMPION spark plugs in a car with an aluminum head" (these days, that's most passenger cars and many SUVs). The reason is (and apparently has been long-known in the auto community) that there is a design flaw in these plugs. When they got hot in the engine, they expand more than other spark plugs, and "weld" themselves into the threaded spark plug hole. Even with the use of anti-seize compound, I'm told that CHAMPION spark plugs have an abnormally-high rate of seizing (compared to other brands, like Bosch or NKG) in aluminum heads.

So, if you value your car, don't use CHAMPION spark plugs, and don't let anyone put CHAMPIONs in it. If you do, you may be in for some COSTLY engine repairs (we got off lucky; if the head had been slightly more damaged, we would have paid $thousands$ to replace the head.

Too bad Federal Mogul won't acknowledge the problem publicly, and maybe put a warning on the box. Better yet, maybe they should figure out why the problem exists, and fix it. In the mean time - AVOID CHAMPION spark plugs.

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