Originally Posted By: RF Overlord
The biggest issue that caused flying spark plugs was improper tightening. Many people insist they have a calibrated arm and "know" exactly how tight to make them without a torque wrench.
A lot of the vehicles with that issue were ex-police or taxi use and were worked on by monkeys who didn't care and either over-tightened, which damaged the threads, or under-tightened, which could allow the plug to work itself loose, especially on the older heads with only a few threads.
Actually, the problem was the few threads engaging the spark plug allowed a number of spark plug threads to extend into the chamber. These threads collected carbon when the engine was operated. When the mechanic removed these plugs, the carbon damaged the aluminum threads in the head. New plugs were installed in compromised holes that barely held the plug. With use, these new spark plugs popped out from combustion pressures.