1A Auto Video Library
Our how-to videos have helped repair over 100 million vehicles.

How to Replace Spark Plug Wire Set 96-00 Chevy Tahoe

Share on:

How to Replace Spark Plug Wire Set 96-00 Chevy Tahoe

Created on: 2012-03-23

Learn how to change the spark plug wires on your 96-00 Chevy Tahoe, equipped with the Vortec 5700, in this video from 1A Auto.

  1. step 1 :Move the air box assembly out of the way
    • Unclip the top of the air box cover.
    • Unclip the mass air flow sensor from the air box base.
    • Remove the 12 mm nut to remove the air box assembly from the throttle body.
  2. step 2 :Replace the spark plug
    • One at a time, disconnect the spark plug wire from the distributer and spark plug.
    • Connect the new wire.
    • Repeat, one wire at a time, till you have changed all of them.
  3. step 3 :reinstall the air box assembly
    • Connect the air flow sensor harnesses.
    • Secure the air box with the 12 mm nut.
    • Clip the air box cover back on.

Tools needed for replacement

  • Ratchets & Related

    Socket Extensions


  • Sockets - Metric

    12mm Socket

Installation Video
Watch video

Brought to you by, your source for quality auto replacement parts and the bets service on the internet. Hi, this is Mike from 1A Auto. I hope this how to video helps you out. Next time you need parts for your vehicle, think of

In this video, we'll show you how to replace the plug wires on this 1996 Chevy Tahoe with a 5.7 liter Vortec motor. This is the same engine and the same procedure for any Chevy or GMC truck SUV from basically about 1995 to '99 or 2000. The only tool you'll need is a 12 millimeter socket with a ratchet and extension to remove your air box assembly. You want to start out, take off your cover here. We're going to unplug this reaching down underneath and you can grab the little clip that holds on, hold the clip back and disconnect that. Disconnect this up here. This comes up. Also going to disconnect this hose right here. You're going to want to remove this nut, this silver one down here. Just fast forward here as we remove that. That is a 12 millimeter nut.

Let's remove that. Basically take this whole apparatus right out. It gives me a lot clear view. What I'd like to do is kind of weigh the spark plug wires out by length. Then you can see right here is your distributor cap and that favors the driver side a little bit. It's a little further over towards the driver side. In general, the driver side wires going to be a little bit shorter and then the one in the front will go into the one and two cylinders will be the longest and on back. Now, alls you do is the one at a time go right to the distributor, grab the wire, twist it and pull and then pull it right down. You can see on this truck, I can see the wires have been replaced before and they used wire ties. You see a wire tie there. Also on this wire here, there's a wire tie. Just going to cut those wire ties. Like I said on this truck, they wired tied a little bit. Your truck should have clips like this, and you just insert a screwdriver into them and pry them up and open and pull the wires out.

I'll cut this wire tie. I'll cut this one. I'm just going take this one out and this one actually goes down to the - that will be the five or the six cylinder. I'll just take my plug wire and just kind of compare it to these here and grab one that's the same size and length. Once I have my wire, the 90 degrees side is always the spark plug side. Just going to take a tiny bit of this dielectric grease and you're just going to put a little bit right into the spark plug boot end. Just take the spark plug in. Hook it into the plug. Going to turn it back and forth. I'm going to spread that grease around and plug it in. Round it up the same way and plug it back into your cap. Here, I'm just going to fast forward to doing the rest of the side. It's just a repeat procedure, you unplug one at a time, take it out, note how it's routed and then put your new one back in. Just try and put basically the same length back together. Beyond that, on this vehicle, I will show you at the end, I do kind of wire it, tie it back into place, the way it was. Not ideal, you want to use the factory clips and insulators. Wire tying it can lead to chaffing of the wires and they could fail prematurely but with this vehicle, we do not have any other choice. All the original clips and routing clips have been -

I did take a couple of plastic wire ties and secure them back on here. This is not really ideal. They really should have plastic insulators because they could chafe on this metal eventually and cause them to fail prematurely. In the absence of having the actual clamps, clip and insulators, as opposed to having them securely fastened is better than just having them kind of hanging lose. You can make sure you get all eight replaced and do a little test start. Make sure everything goes correctly and the engine runs nice and smooth. After that, put your air and tank back together. You can put it on into place. Make sure to reconnect both of the connections, the airflow sensors and put it back into the air box, tighten up that 12 millimeter nut. Reconnect the PVC, put your air filter in and your air box together. Even though I didn't loosen any of the clamps on the air and tank hose, I did check and I found that one was lose. Just make sure you tighten up those connections and check them.

We hope this helps you out. Brought to you by, your source for quality auto replacement parts and the bets service on the internet. Please feel free to call us toll-free, 888-844-3393. We're the company that serves you on the internet and in person.

Tools needed for replacement:

    Ratchets & Related

  • Socket Extensions
  • Ratchet

  • Sockets - Metric

  • 12mm Socket

Search Videos
Go To Top

Same Day Shipping

Need your part faster? Choose expedited shipping at checkout.

Guaranteed To Fit

Highest quality, direct fit replacement auto parts enforced to the strictest product standards.

USA Customer Support

Exceeding customers' expectations, our team of passionate auto enthusiasts are here to help.

Instructional Video Library

Thousands of how-to auto repair videos to guide you step-by-step through your repair.